operation/maintenance - caterpillar · pdf fileoperation/maintenance manual ... by the...

INSERO EQUIPMENT | 11002 SAPP BROTHERS DRIVE | OMAHA, NE 68138INSEROEQUIPMENT.COM | 855.604.2117

H E A T E R

OPERATION/MAINTENANCEAND

PARTS MANUAL

READ INSTRUCTIONS PRIOR TO STARTING HEATERES

INSPECTION CHECK LISTPREPARING THE INSERO HEATER FOR DELIVERY OR RENTAL

The Insero Equipment Heater requires service as well as proper operation in order to provide the performance and safety for which it was designed. Never deliver or put a machine into service with known defects or missing instructions or decals. Always instruct the customer in the proper operation and safety procedures as described in the operator’s manual.

Check List: » Visually inspect the equipment to ensure that all instructions and

decals are in place and legible. » Check the hitch assembly and safety tow chains. » Check the jack to make sure it operates properly. » Inspect the tires to ensure proper inflation and condition. » Check lug nuts and torque to 80-90 ft. lbs. After first 100 miles of towing

lug nuts should be re-torqued. » Check the ground rod cable and the ground lug. Make sure they are

clean, undamaged and functional. » Make sure the battery is fully charged and the terminals are tight and

clean. Ensure the electrolyte is at the correct level. » Check the service intervals for oil filters, fuel filters, air cleaner and

engine oil. » Check the oil, fuel and coolant levels. » To ensure proper operation, start engine and turn heaters on.

SAFETY WARNING!

NEVER ALLOW ANYONE TO OPERATE THE EQUIPMENT WITHOUT PROPER TRAINING.

ALWAYS READ THE MANUAL FIRST.INSERO EQUIPMENT | 11002 SAPP BROTHERS DRIVE | OMAHA, NE 68138

INSEROEQUIPMENT.COM | 855.604.2117

TABLE OF CONTENTSWARRANTY STATEMENTSInsero Heater Warranty, Procedures & Claim Form .......................................................................... 1-3

Marathon Electric Generator Warranty ..................................................................................................4

Cat C1.5 Tier 4 Diesel Engine Warranty ............................................................................................... 5-7

OPERATION/MAINTENANCE MANUALSpecifications ...........................................................................................................................................8

Installation Instructions ...........................................................................................................................9

Operating Instructions ........................................................................................................................... 10

Maintenance Instructions ...................................................................................................................... 11

Cleaning Procedure ................................................................................................................................ 12

Temperature Feeler Adjustment ............................................................................................................ 13

Settings ...............................................................................................................................................14-16

Primary Controls (Honeywell & Genisys Controls) ..........................................................................17-19

Burner Assembly Components .........................................................................................................20-21

Limits, Fan Switches and Temperature Feelers ................................................................................... 22

Heat Exchanger for Oil Units ................................................................................................................. 23

IDF 500 Front View & Back View w. Labels .....................................................................................24-25

HEATER PARTS MANUALHeater Exterior ...................................................................................................................................26-27

Engine Compartment .............................................................................................................................. 28

Battery Components ............................................................................................................................... 29

Control Panel ........................................................................................................................................... 30

Accessories ............................................................................................................................................ 31

Trailer Components ................................................................................................................................. 32

Electrical Components ........................................................................................................................... 33

Accessories ............................................................................................................................................ 34

Burner Fuel System ................................................................................................................................ 35

Placards and Decals .............................................................................................................................. 36

SCHEMATICS/WIRING DOCUMENTSTrailer Harness/Control Panel Wiring Diagram .................................................................................... 37

E-Stop and Air Intake Wiring Diagram .................................................................................................. 38

Engine Harness Wiring Diagram ........................................................................................................... 39

Fan Motor, Honeywell and Genisys Control Wiring Diagram .........................................................40-42

Trailer Schematics .............................................................................................................................43-44

TROUBLE SHOOTINGTrouble Shooting ................................................................................................................................45-46

WARRANTY STATEMENTS

INSERO EQUIPMENT® HEATER LIMITED WARRANTY

Diversified Products, LLC dba Insero Equipment

(hereinafter, “Insero”) warrants its Insero Equipment®

Heater to be free from defects in materials and

workmanship for period of one (1) year or 1,000 hours,

whichever occurs first, from the date of delivery to the

original purchaser.

If a defect in material or workmanship is found during

the warranty period, Insero will, during normal working

hours and through an authorized Insero Equipment

Heater dealer or other source approved by Insero, repair

or replace (at Insero’s option) the defective goods or

parts, without charge to the original purchaser. This

warranty does not renew or extend with repaired or

replaced goods or parts. All warranties are from the date

of delivery of the original product.

This warranty covers the trailer structure from bumper to

bumper. This warranty is not applicable to items which

are individually covered by the component

manufacturers, such as the base engine which is

warranted according to the terms and conditions supplied

by the Caterpillar Engine Division. All warranty

information from such other manufacturers is provided

within or accompany these goods.

This warranty is non-transferrable and applies only to the

original purchaser.

EXCLUSIONS FROM THIS WARRANTY

This warranty does not cover:

Conditions resulting from misuse, natural calamities,

improper storage, negligence, alteration, accident,

unapproved attachments or usage which is contrary to

the intended purpose.

Conditions resulting from the failure to perform routine

maintenance.

Items normally designed to be periodically replaced by

the equipment owner during the equipment life due to

normal wear and tear.

Damage to the finish of the trailer or other appearance

parts caused by wear.

PURCHASER RESPONSIBILITIES

The purchaser is responsible for:

Providing proof of purchase and the date of delivery.

Local taxes, if applicable.

All costs associated with transporting the equipment to

and from the authorized Insero Equipment Heater

dealer or other source approved by Insero.

Premium or overtime labor costs.

Costs to investigate complaints, unless the problem is

caused by a defect in material or workmanship.

Giving timely notice of a warrantable failure and

promptly making the equipment available for repair.

Performance of required maintenance and items

replaced due to normal wear and tear.

Freight on goods and parts returned to factory for

inspection or repair.

SHIPPING Shipping charges are paid under this warranty by Insero

for replacement parts only. Insero will not be held

responsible for delays in shipping. In the event it is

necessary to return goods or parts to Insero for repair or

inspection, purchaser shall be responsible for and must

prepay such shipping expense.

WARRANTY ACTION In order to recover under this warranty, the original

purchaser must submit a claim to Insero or an authorized

Insero Equipment Heater dealer within 30 days of

discovery of the alleged defect. To be covered by this

warranty, service must be performed by an authorized

Insero Equipment Heater dealer or other source approved

by Insero. It is the responsibility of the purchaser to

transport the equipment to the service shop of an

authorized Insero Equipment Heater dealer or other

approved source for service.

EXCLUSIVE REMEDY AND LIMITATION OF

LIABILITY The obligation of Insero under this warranty is limited

solely to repair or replacement of defective goods or

parts. THIS WARRANTY IS EXCLUSIVE AND IN

LIEU OF ALL OTHER WARRANTIES, EXPRESS OR

IMPLIED, ARISING BY LAW OR CUSTOM,

INCLUDING IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE. IN NO EVENT SHALL

DIVERSIFED BE LIABLE FOR SPECIAL, INDIRECT

OR CONSEQUENTIAL DAMAGES INCLUDING

BUT NOT LIMITED TO LOSS PROFITS, OTHER

COMMERCIAL LOSSES, INCONVENIENCE, OR

COST OF RENTAL OR REPLACEMENT

EQUIPMENT. THE LIABILITY OF INSERO UNDER

THIS WARRANTY SHALL IN NO WAY EXCEED

THE PURCHASE PRICE OF THE INSERO

EQUIPMENT HEATER.

Some states or providences do not allow exclusion or

limitation of incidental or consequential damages, or

exclusions or limitations of implied warranties or conditions, so such exclusions or limitations may not

apply.

INSEROEQUIPMENT.COM | 855.604.2117 1

INSERO EQUIPMENT HEATER WARRANTY PROCEDURE

FOR PRODUCTS MANUFACTURED BY INSERO EQUIPMENTAny component, sub-assembly, or device manufactured by Insero Equipment will be warranted as stated in the Insero Equipment Limited Warranty.

As stated by the Insero Equipment Limited Warranty, if a component, sub-assembly or device manufactured by anyone other than Insero should fail, it shall be warranted by its manufacturer, however, in some cases, this will be handled through the Insero Equipment Warranty Department. Therefore, notification must be made to Insero Equipment upon failure for proper warranty procedure.

STANDARD WARRANTY PROCEDURE:1. Upon notice of warrant able failure, information should be gathered specific to the cause and results of the failure. Warranty claim requests must be filed within 30 days of failure.

2. Contact the Insero Equipment Service Part & Service Department and explain the situation, including model and serial number of machine, hours on machine, etc.

3. If replacement of components or sub-assembly is determined necessary, Insero Equipment Service Parts & Service Department will advise as to the proper procedure to either repair or replace as necessary and warranty coverage available. Insero Equipment Service Parts & Service Department will determine if the parts can be supplied for replacement without being returned for inspection. When it is necessary to return parts for inspection, Insero Equipment will issue a Returned Goods Authorization (RGA) Number for the return of the components. All parts to be returned shall be shipped prep aid by customer. Insero Equipment will ship replacement parts via ground freight only and invoice the customer for parts and freight as necessary. Expedited freight specified by customer will be billed to the customer. Upon examination of parts, Insero Equipment will determine warranty coverage and will issue credit for replacement parts and labor based on the criteria listed above. All defective parts must be returned within 30 days for examination for credit to be issued.

4. If field repairs are necessary, contact the Insero Equipment Parts & Service Department for prior authorization or warranty may be voided. Any repairs approved by Insero Equipment will be paid as deemed appropriate by Insero Equipment upon receipt of claim, if filed within 30 days of failure.

INSERO EQUIPMENTCONTACT: AARON JOHNSON11002 SAPP BROTHERS DRIVEOMAHA, NE 68138PHONE: 855.604.2117FAX: 402.891.7565

INSEROEQUIPMENT.COM


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Total labor cost of repair/replacement of parts only: LABOR $

Total cost of part(s) used in repairing unit: PARTS $

Total amount claimed, parts and labor combined: TOTAL $

Filed by: _____________________________ Title: _____________________________

Labor performedby: _________________________________ Contact: _______________________

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Product Name: __________________ Model #: ____________ Serial #: ____________ Hours: _____

Date Purchased:____/____/____ Date Put In Service:____/____/____ Date of Failure:____/____/____

Description of Failure:________________________________________________________________

Cause of Failure (if known):____________________________________________________________

For office use only

Claim is / is not granted. Authorized signature: _____________________ ____ Date: ____/____/____

Comments: ________________________________________________________________________________ _________________________________________________________________________________________

Action Directed: _____________________________________________________________________________

TOTAL CREDIT: $_________________

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Insero Equipment Heater Warranty Claim Form

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INSERO EQUIPMENT ATTN: SERVICE 11002 SAPP BROTHERS DRIVE OMAHA, NE 68138 PHONE: 800.628.6025 FAX: 402.891.8600 INSEROEQUIPMENT.COM

WARRANTIES TO DISTRIBUTORS AND INDUSTRIAL ORCOMMERCIAL CUSTOMERS

This warranty is extended only to Marathon’s distributors and industrial or commercial customers and does not apply to consumer purchasers. This warranty applies to all generator and related parts sales.

WARRANTY PERIOD - (a) Marathon warrants Standby Duty Generators manufactured by or for it to be free from defects in materials and workmanship and to conform to Marathon’s written specifications fora period of 24 months from date of startup, 30 months from date of shipment, or 1000 hours in use, ichever period shall expire first. (b) Marathon warrants the Continuous Duty Generators manufactured by or for it to be free from defects in materials and workmanship and to conform to Marathon’s written specifications for a period of 12 months from date of startup or 18 months from date of shipment, whichever period shall expire first.

WARRANTY REMEDIES - If, prior to expiration of the foregoing applicable warranty period, any of such products shall be proved to Marathon’s satisfaction to be defective or nonconforming, Marathon will repair or replace such defective equipment or components thereof, F.O.B. Marathon’s plant or other destination designated by Marathon, or will refund or provide Buyer with a credit in the amount of the purchase price paid therefor by Buy-er, at Marathon’s sole option. Buyer’s exclusive remedy and Marathon’s sole obligation under this warranty shall be limited to such repair or replacement, F.O.B. Marathon’s plant or other destination designated by Marathon, or refund or credit by Marathon, and shall be conditioned upon Marathon’s receiving written notice of any defect within a reasonable period of time (but in no event more than sixty (60) days) after it was discovered or by reason-able care should have been discovered. In no event shall Marathon’s liability for such defective or nonconforming products exceed the purchase price paid by Buyer therefor.

EXCLUSIONS - This warranty does not (i) cover shipping expenses to and from Marathon’s factory or other desti-nation designated by Marathon for repair or replacement of defective equipment or any tax,duty, custom, inspection or testing fee, or any other charge of any nature related thereto, nor does it cover the costs of disassembling or removing defective equipment or reassembling, reinstalling, or testing repaired or replaced equipment or finishing the reinstallation thereof, (ii) apply and shall be void with respect to equipment operated in excess of rated capacity or otherwise not in accordance with installation, maintenance, or operating instructions or requirements, to equipment repaired or altered by others than Marathon or Marathon’s authorized service agencies, or to equipment which was subjected to abuse, negligence, misuse, misapplication, accident, damages by circumstances beyond Marathon’s control, to improper installation (if by others than Marathon), operation, maintenance or storage, or to other than normal use or service, and (iii) apply to equipment or com-ponents not manufactured by or for Marathon. With respect to equipment or components not manufactured by Marathon, Marathon’s warranty obligations shall in all respects conform and be limited to the warranty actually extended to Marathon by its suppliers, but in no event shall Marathon’s obligations be greater than those pro-vided under Marathon’s warranty set forth in this Section 10.

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES (EXCEPT TI-TLE), INCLUDING, WITHOUT LIMITATION, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. NO EMPLOYEE, REPRESENTATIVE, OR AGENT OF MARATHON OTHER THAN AN OF-FICER OF MARATHON IS AUTHORIZED TO ALTER OR MODIFY ANY PROVISION OF THIS SECTION 10 OR TO MAKE ANY GUARANTEE, WARRANTY, OR REPRESENTATION, EXPRESS OR IMPLIED, ORALLY OR IN WRITING, WHICH IS CONTRARY TO THE FOREGOING.

Any description of the equipment, whether in writing or made orally by Marathon or Marathon’s agents, speci-fications, samples, models, bulletins, drawings, diagrams, engineering sheets or similar materials used in con-nection with Buyer’s order are for the sole purpose of identifying the equipment and shall not be construed as an express warranty. Any suggestions by Marathon or Marathon’s agents regarding use, application or suitability of the equipment shall not be construed as an express warranty unless confirmed to be such in writing by Mara-thon’s authorized officer.


CATERPILLAR LIMITED WARRANTYNew and Remanufactured 3000 Family, C0.5 through C4.4,

and ACERT Engines Worldwide

Caterpillar Inc. or any of its subsidiaries (“Caterpillar”) warrants new and remanufactured 3000 Family, C0.5through C4.4, and ACERT industrial engines sold by it, to be free from defects in material and workmanship. ACERTindustrial engines refer to the C6.6, C7, C7.1, C9, C9.3, C11, C13, C15, C18, C27, and C32 engine models.

This warranty does not apply to engines sold for use in marine applications, engines in machines manufacturedby Caterpillar, or Cat batteries. These products are covered by other Caterpillar warranties.This warranty is subject to the following:WARRANTY PERIODThe standard warranty period for new and remanufactured 3003, 3011, 3013, 3014, 3024, C0.5, C0.7, C1.1, C1.5,C1.6, C1.7, and C2.2 engines used in mobile agricultural, industrial, locomotive, and petroleum applications (ex-cluding Petroleum Power Systems) is 24 months or 2000 hours, whichever occurs first (with the first 12 months at unlimited hours) after the date of delivery to the first user.The standard warranty period for new and remanufactured 3034, 3044, 3054, 3056, C3.4, C4.4, and C6.6 engines used in mobile agricultural, industrial, locomotive, and petroleum applications (excluding Petroleum Power Sys-tems) is 24 months or 3000 hours, whichever occurs first (with the first 12 months at unlimited hours) after thedate of delivery to the first user.For new and remanufactured 3034, 3044, 3054, 3056, C0.5, C0.7, C1.1, C1.5, C1.6, C1.7, C2.2, C3.4, C4.4, and C6.6 engines:

» Low Usage: In cases where the engine use does not exceed 500 hours per year, the warranty period is ex tended for one additional year or until the engine use reaches a total of 1500 hours in the 3rd year of war-ranty, whichever occurs first, after the date of delivery to the first user.

The standard warranty period for new and remanufactured C7, C7.1, C9, C9.3, C11, C13, C15, C18, C27, and C32 engines (i) for use in mobile agricultural applications, 24 months after the date of delivery to the first user and (ii) for industrial, locomotive, and petroleum applications (excluding Petroleum Power Systems) 24 months or 3000 hours, whichever occurs first (with the first 12 months at unlimited hours), after the date of delivery to the first user.The standard warranty period for rotating electrics (i) used on new and remanufactured 3000 Family, C0.5 through C4.4 and C6.6 engines is 12 months from the date of engine delivery to the first user, and (ii) used on new andremanufactured C7, C7.1, C9, C9.3, C11, C13, C15, C18, C27, C32 engines is 24 months or 3000 hours, whichever oc-curs first (with the first 12 months at unlimited hours) after the date of engine delivery to the first user.The standard warranty period for Petroleum Power Systems is 12 months, after the date of delivery to the first user.EXTENDED WARRANTYFor all new and remanufactured 3000 Family, C0.5 through C4.4, and ACERT engines:

» Major Components: A major components extended warranty applies solely to the following components: cylinder block casting, cylinder head casting, crankshaft (excluding bearings), camshaft, and connecting rods. These parts are warranted against defects in material and workmanship for 36 months after the date of delivery to the first user. This warranty runs concurrently with the standard warranty period.

CATERPILLAR RESPONSIBILITIESIf a defect in material or workmanship is found during the standard warranty period or the extended warranty period, as applicable, Caterpillar will, during normal working hours and at a place of business of a Cat dealer or other source approved by Caterpillar:

» Provide (at Caterpillar’s choice) new, remanufactured, or Caterpillar approved repaired parts or assembled components needed to correct the defect.


CATERPILLAR LIMITED WARRANTY

Note: New, remanufactured, or Caterpillar approved repaired parts or assembled components provided under the terms of this warranty are warranted for the remainder of the warranty period applicable to the product in which installed as if such parts were original components of that product. Items replaced under this warranty become the property of Caterpillar.

» Replace lubricating oil, filters, coolant, and other service items made unusable by the defect.

» Provide reasonable and customary labor needed to correct the defect, including labor to disconnect the product from and reconnect the product to its attached equipment, mounting, and support systems, if required, provided that (i) for new and remanufactured 3003, 3011, 3013, 3014, 3024, C0.5, C0.7, C1.1, C1.5, C1.6, C1.7, and C2.2 engines, labor to disconnect and reconnect the product is provided up to 10 hours (labor to disconnect and reconnect the product in excess of 10 hours is the user’s responsibility), and (ii) for new and remanufactured 3034, 3044, 3054, 3056, C3.4, C4.4, and C6.6 engines, the labor to disconnect and reconnect the product is provid-ed up to 15 hours (labor to disconnect and reconnect the product in excess of 15 hours is the user’s responsibil-ity).

For new and remanufactured 3000 Family and C0.5 through C7.1 engines: » Provide travel labor, up to four hours round trip, if in the opinion of Caterpillar, the product cannot reasonably

be transported to a place of business of a Cat dealer or other source approved by Caterpillar (travel labor in excess of four hours round trip, and any meals, mileage, lodging, etc. is the user’s responsibility).

For new and remanufactured C9, C9.3, C11, C13, C15, C18, C27, and C32 engines: » Provide reasonable travel expenses for authorized mechanics, including meals, mileage, and lodging when

Caterpillar elects to make the repair on-site.

USER RESPONSIBILITIESThe user is responsible for:

» Providing proof of the delivery date to the first user. » Labor costs, except as stated under “Caterpillar Responsibilities.” » Travel expenses not covered under “Caterpillar Responsibilities.” » All costs associated with transporting the product to and from the place of business of a Cat dealer or other

source approved by Caterpillar. » Premium or overtime labor costs. » Parts shipping charges in excess of those that are usual and customary. » Local taxes, if applicable. » Costs to investigate complaints, unless the problem is caused by a defect in Caterpillar material or workman

ship. » Giving timely notice of a warrantable failure and promptly making the product available for repair. » Performing all required maintenance (including use of proper fuel, oil, lubricants, and coolant) and items

replaced due to normal wear and tear. » Allowing Caterpillar access to all electronically stored data.

LIMITATIONSCaterpillar is not responsible for:

» Failures resulting from any use or installation that Caterpillar judges improper. » Failures resulting from attachments, accessory items, and parts not sold or approved by Caterpillar. » Failures resulting from abuse, neglect, or improper repair. » Failures resulting from user’s delay in making the product available after being notified of a potential product

problem. » Failures resulting from unauthorized repair or adjustment, and unauthorized fuel-setting changes. » Damage to parts, fixtures, housings, attachments, and accessory items, which are not part of the engine.


CATERPILLAR LIMITED WARRANTY

For products operating outside of Australia, Fiji, Nauru, New Caledonia, New Zealand, Papua New Guinea, the Solomon Islands, and Tahiti, the following is applicable:

NEITHER THE FOREGOING EXPRESS WARRANTY NOR ANY OTHER WARRANTY BY CATERPILLAR, EXPRESS OR IMPLIED, IS APPLICABLE TO ANY ITEM CATERPILLAR SELLS, WHICH IS WARRANTED DIRECTLY TO THE USER BY ITS MANUFACTURER. THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, EX-CEPT CATERPILLAR EMISSION-RELATED COMPONENT WARRANTIES FOR NEW ENGINES, WHERE APPLICABLE. REMEDIES UNDER THIS WARRANTY ARE LIMITED TO THE PROVISION OF MATERIAL AND SERVICES, AS SPECI-FIED HEREIN.

CATERPILLAR IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

CATERPILLAR EXCLUDES ALL LIABILITY FOR OR ARISING FROM ANY NEGLIGENCE ON ITS PART OR ON THE PART OF ANY OF ITS EMPLOYEES, AGENTS, OR REPRESENTATIVES IN RESPECT OF THE MANUFACTURE OR SUPPLY OF GOODS OR THE PROVISION OF SERVICES RELATING TO THE GOODS.

IF OTHERWISE APPLICABLE, THE VIENNA CONVENTION ON CONTRACTS FOR THE INTERNATIONAL SALE OF GOODS IS EXCLUDED IN ITS ENTIRETY.

For personal or family use engines operating in the USA, its territories and its possessions, some states do not allow limitations on how long an implied warranty may last nor allow the exclusion or limitation of incidental or consequential damages. Therefore, the previously expressed exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights, which vary by jurisdiction. To find the location of the nearest Cat dealer or other authorized repair facility, call (800) 447-4986. If you have questions concerning this warranty or its application, call or write:

In USA and Canada: Caterpillar Inc., Engine Division, P. O. Box 610, Mossville, IL 61552- 0610, Attention: Customer Service Manager, Telephone (800) 447-4986. Outside the USA and Canada: Contact your Cat dealer.


OPERATION/

MAINTENANCE

MANUAL

SPECIFICATIONS

NOTE: -These heaters are intended for use primarily as temporary heating of buildings under construction, alteration or repair

MAXIMUM ALLOWABLE DUCT LENGTHS (IDF 350 & IDF 500 )

DISCHARGE OUTLET

Two 12“ ducts

One 16“ duct

LENGTH

24 Feet

45 Feet

Flue size-6” on all units

For the IDF500 HS, the maximum allowed ducting is 50' for the 12" X 2 and 100' for the 16".

MODEL IDF350-II IDF500 IDF500HS

MAXIMUM INPUT

350,000 BTU/HR

500,000 BTU/HR

500,000 BTU/HR

NOZZLE SIZE

2.00 USGPH45’ B (SOLID)

2.5O USGPH60’B (SOLID)

2.5O USGPH60’B (SOLID)

PUMP PRESSURE

125 P.S.I. MAXIMUM

140 P.S.I. MAXIMUM

140 P.S.I. MAXIMUM

FUEL TANK CAP.

35 IMP GALS. 42 US GALS.



ELECTRICAL SUPPLY

115 VOLT 15 AMP

115 VOLT 20 AMP

115 VOLT 20 AMP

HEATED AIR (W/O DUCT) 2500 CFM

3100 CFM 3100 CFM

APROX. RUN TIME

13 HOURS 11 HOURS 11 HOURS

APPROVAL AGENCY

DRY WEIGHT

467 LBS. 467 LBS. 485 LBS.


INSTALLATION INSTRUCTIONS

1. The recommendations of local authorities having jurisdiction must be followed. For recommended Installation practices refer to C.S.A. Standard B149. (CANADA)

2. When firing the unit in an enclosed area 3 square feet must be provided to allow the free entry of the air required for operation.

3. For electrical supply, use 3 wire receptacle with “U” ground.

4. Do not operate the unit in partly ventilated areas without a flue pipe or in close proximity to combustible surfaces or materials.

NOTE: Installation clearances are as follows: Top - 3 inches Discharge End - 10 feet

Sides - 6 inches Vent Connector - 18 inches Burner End - 2 feet Floor - Combustible

FROSTFROST

2 FT.MIN.

2 FT.MIN.

FLUE WITHVERTICAL RUN

FLUE WITH HORIZONTAL RUN

RISE RATIO1 IN 10

INSTALLATION CLEARANCES

FLUE PIPE CONNECTIONS

When the heater is connected to a flue pipe the flue pipe shall terminate in a verticalsection at least two feet long. Horizontal runs should have rise ratio of 1 in 10 away

from the heater. The chimney should have .02” W.C. draft to ensure safe operation of the unit. Where down drafts are liable to occur a vent cap should be used. All venting should correspond with the CSA B149 standard or local codes.


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OPERATING INSTRUCTIONS

TO START HEAT 1. Ensure unit is on flat, level ground before starting, canopy and fan guards must be closed. 2. Flip switch to “OFF” position

3 Check fuel level ( 2-4 gallons to start) 4. Plug in supply cord to 115 volt outlet. 5. Flip switch to “MANUAL” position. 6. For thermostat operation flip switch to “THERM” position. 7 There will be a 5 second safe start check, a 15 second pre purge then the burner will fire.IF HEATER FAILS TO START 1. Press manual reset button on burner relay.

2. Check for low voltage condition and 115 volt supply.3. Check fuel filter and suction tubing.4. Check nozzle assembly.

NOTE: If unit has been reset a number of times without ignition there will be an accumulation of oil in the combustion chamber! Do the following:

1. Make sure unit is sitting on level ground to ensure the excess oil drain out of the secondary chamber (via small drain hole located on outer shell of heat exchanger).

2. Allow unit to drain for 15-20 minutes or until all oil has drained out.3. Upon ignition excessive amounts of smoke will be present until all excess oil has been burnt from the heat exchanger. 4. When the unit has stabilized and the burner set up to operate properly, shut off the switch. Let the fan cool down the chamber and stop.

IF UNIT STILL DOES NOT START REFER TO THE TROUBLE SHOOTING GUIDE PAGE 6

CAUTION

1. Do not start heater when excess oil has accumulated in chamber.2. Do not fill tank while unit is operating.3. Do not shut off by disconnecting supply cord. The heat exchanger

should be properly cooled before power shutdown.4. In no case should extension cords be smaller than 12 A.W.G. If cord

is longer than 50’ use 10 A.W.G. minimum.5. Do not use gasoline, crankcase oil or heavier than No. 2 furnace oil.6. Always maintain adequate fuel supply.

ELECTRICAL REQUIREMENTS:15 amp circuit IDF 350-II20 amp circuit IDF 50020 amp circuit IDF 500HS

TO STOP HEATERzFlip switch to “OFF” position. The supply fan will continue to operate until the heat exchanger Has sufficiently cooled. Do not disconnect main power until supply fan has stopped running.

!WARNING!: BEFORE MOVING ANY GUARDS OR SAFETIES DISCONNECT THE MAIN POWER AS THE SUPPLY FAN WILL CYCLE AUTOMATICALLY.


O.H.V. MAINTENANCE INSTRUCTIONS

!WARNING!: Heaters should be fully serviced annually to ensure proper Performance. Maintenance should be performed by trained personnel

only. Incorrect maintenance may result in improper operation and serious injury.

HIGH LIMIT SWITCH The limit switch should be checked every heating season to ensure the burner will

o shutdown if temperature exceeds 220 F. (This can be done by restricting the air flow through the unit. After tests are complete, remove restricters as both 12” ducts must be open for proper operation).

FAN SWITCH The fan switch has been selected to allow for preheating of the heat exchanger to ensure that only heated air is allowed to enter the space. Upon satisfying the need for heat, the fan switch will continue to run the supply fan until the heat exchanger has cooled sufficiently. This feature will help prolong the life of your heat exchanger.

FUEL FILTER Replace cartridge once every week of normal usage or sooner, depending upon fuel quality.

FLAME DETECTOR When doing maintenance, turn on machine and run. After having machine run for over 10 seconds, press red button on primary control. Hold for one second and then release. If light flashes once or twice, cad cell is functioning properly. If flashes three times, check alignment and proper flame. If correct a cleaning of the face of the cad cell with a soft non abrasive cloth is recommended. If light flashes four times, follow above steps. If flashing four times persists, replace cad cell. LED FLASHES CAD CELL RESISTANCE

1 0-400 Ohms2 400-800 Ohms3 800-1600 Ohms4 >= 1600 Ohms

BURNER The electrode spacing must be checked and adjusted, if necessary after every nozzle change. Nozzle should be replaced monthly or sooner, depending on fuel quality and length of time unit is running or if burner cannot be set up to operate properly. Nozzle size and type are

marked on the rating plate. Please see page 6 for recommendation of nozzle size based upon temperature & fuel usage.

ELECTRICAL Ensure all conduit (BX) connectors are tight. Check inside connections in control box to ensure good connections. Check marrettes.

FAN Check for dust or dirt build up on blades. Check for tightness of the set screw. Run heater to check for fan vibration. Replace fan blade if vibration is noticeable.

MOTORS No lubrication is necessary since the bearings are the sealed type. Clean motor of existing dust or dirt.

FUEL SYSTEM Periodically remove fuel tank drain plug and clean tank. Do not store unit containing

furnace oil for long periods. The quality of fuel oil will affect light off at low ambient otemperatures, #1 fuel oil or kerosene are recommended for temperatures below -10 C /

o8 F. FUEL PUMP

Check fuel pump pressure on a regular basis. This should be checked at the bleeder screw. HEAT EXCHANGER

If a smokey condition continues even after adjusting the air band assembly, the heat exchanger should be thoroughly cleaned as per below.


CLEANING PROCEDURE1. Remove front cap. (48205, 48205A or 20205)2. Remove cover panel (jacket to front). (48119 or 20119)3. Remove fan thermostat cover on outer jacket (the one nearest the burner). (48112A)

Loosen thermostat and remove from the jacket. Remove high limit/fan switchcover.(48112). Remove the two screws that are on jacket, at the 3’o’clock & 9 o’clock position 8 inches from front of unit.

4. Slide heat exchanger out of jacket and place front face down on floor.5. Access for combustion chamber and heat exchanger cleaning is obtained through

the burner head opening and by removing the heat exchanger cap ring(s) (48115 or50115).

6. To reassemble, reverse procedure. If you need assistance, please contact the factory.

Close canopy and ensure fan guards are in proper position before trying to restart the unit..

COMBUSTION AIR ADJUSTMENTS

****For proper combustion air adjustment a calibrated gas analyzer and smoke tester should be used to ensure complete combustion. Air adjustment should be made at the correct input and be adjusted to achieve 10-12% CO2. For optimum combustion efficiency the combustion air control should be set to provide no more than a No. 1 smoke (Bacharach Scale). The Beckett burner has a calibrated air band, which will assist in adjusting the primary air for a good oil/air mixture. Adjust air band supply by loosening lock screws and moving air shutter (B48254) and if necessary the bulk air band. Begin by reducing the air until the unit begins to produce smoke. Increase air until no smoke is produced. Check for excessive heat build up in the heat exchanger. Insufficient air will cause flame impingement and reduced heat exchanger life. Increase air until heat build up has been eliminated. Check for proper ignition. Once satisfied re- tighten all screws and locking mechanisms.

This adjustment is to be carried out while the unit is operating and after 5 minutes of firing. Rotating the air bands on the burner housing makes the adjustment.

SHUTTERUNIT MODEL

4.0

2.0

IDF 350-II

IDF 500

AIR SETTINGS

BAND

0

1

BURNER MODEL

CF 500

CF 800

***Note: The above settings are approximations based upon clean equipment in proper working order. Combustion air adjustments will vary with location, altitude and type of fuel used.

6

UNIT NOZZLE (USGPH)

OHV 350 1.5X60’SOLID

IDF 350 1.75 X 45’SOLID

OHV 500 2.25 X 60’ SOLID

IDF 500 2.25 X 60’ SOLID

Due to the increased density of #2 oilat colder temperatures, kerosene fuel mustbe used or the oil nozzles change as followsat temperatures below 8°F. / -10°C.;


TEMPERATURE FEELER ADJUSTMENT: (Attached to fan switch)

ALWAYS MAKE SURE THAT THE TEMPERATURE FEELER IS TOUCHING THE HEAT EXCHANGER!!

The temperature feeler provides air flow over the fan switch, which regulates the cycling of the fan.The temperature feeler can be adjusted for different outside temperatures, by rotating the locationof the temperature feeler holes. This will provide optimum performance of the unit in differentapplications, and will reduce or eliminate unnecessary fan cycling.

IF SURROUNDING AIR IS WARM (EG., -5 C or 23 F, indoor application):

TURN THE TEMPERATURE FEELER SO THAT THE HOLES ARE PARALLEL WITH THE HEAT EXCHANGER, AND ENSURE THAT NOTHING IS BLOCKING THE AIR FLOW (EG., SCREWS). BY DOING THIS THE FAN SWITCH WILL REMAIN COOL AND NOT OVERHEAT. (SEE FOLLOWING)The fan switch is located under the high limit/fan cover which is mounted on the jacket close to front of unit.The switch can be adjusted by using a flat-headed screw driver and turning it clockwise or counter clock wise to desired temperature.

IF SURROUNDING AIR IS COLD (EG., under -5 C or 23 F)

TURN THE TEMPERATURE FEELER SO THAT THE HOLES ARE CLOSED OFF AS THE AIR GOESOVER THE HEAT EXCHANGER, THIS WILL REDUCE FAN CYCLING, UNIT SHUTDOWN, ETC.(SEE FOLLOWING)

.

Indoor and outdoor settings of fan switch

Indoors & if surrounding air is warm i.e. -5C/23F-Fan switch should be set to 115’ or higher so as to shut down unit when heat exchanger is properly cooled, also keeps fan motor from excessive running on when discharging cooler air.

Outdoor-Fan switch should be set between 100’-90’. The colder the temperature the lower the setting.


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ELECTRODE SETTINGS FOR IDF350-II & IDF500 MODELS

SLIDE PLATE SETTINGS FOR IDF350-II & IDF500 MODELS

IDF350-II 4-5IDF500 6


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JUNCTION BOX OF IDF350-II & IDF500

48006 GREEN LIGHT W/LEADS

48005 RED LIGHTS W/LEADS

48216 15 AMP BREAKER REPLACES FUSE & FUSEHOLDER

48184 CLEAR COVER FOR 48185B HONEYWELL CONTROLLER


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THE SETTING OF THE “Z” DIMENSION ON IDF350-II & IDF500 MODELS

0 Install nozzle line assembly

• Insert the nozzle line assembly into the bumer air tube. Reference Figure 6.

• Slide the secondmy adjusting plate (Figure 7, item f) completely to the left on the indicator adjusting plate (item e) . Finger tighten acom nut (item c) to secure the two plates together. Slide both plates completely to the right (Indicator Plate will read 0) . Tighten fastener (item d) .

• Install the spline nut on the end of the nozzle line, leaving the nut loosely placed so the plates can be moved.

Figure 6 • Nozzle line assembly in bumer

CF800 1·3{4"'

0 Set dimension Z

500M

• Loo:;.e:n fastener c m Figurl!' -. Slide the nozzle line and plate assemblv until dimensiolll Z in Figun? 6 is: CH-00- 1-9116" :~::11 16''

CF800 - 1-.V.r' : Ll6'' .

\Vhen d.imeruio:c Z (from end of air tube to fiat area of front face of head) is correctly se t. tighten a~com. nut (item c).

• Atta~h the oi1 line from the oil , .ai,·e to the nozzle line end. Tigihten. se<:ourely.

• :Before proceeding. check dimension Z oJ:.oe agam. l oo; en acom nut ( mf J:.ece:;.sacy to rei!)l).:>ition the nozzle line. Oll!.ce dimension Z is ~et, do rror loose11 rfre r.<:onl mu (imuj (' cgai11. Note that for the ~tting of fastener d, mer to bJitial H r;atl Position procedure OD Page l l .


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PRIMARY CONTROLS USED ON OHV HEATERS (PAST & PRESENT)

48185 WHITE ROGERSTHIS CONTROL HAS INSTANT LIGHT OFF (NO PRE PURGE) AND CONTINUOUS SPARK.

48185A-R8184 HONEYWELLSAME OPERATION AS THE WHITE ROGERS CONTROL.

48185B-R7184B HONEYWELLTHIS IS THE LATEST PRIMARY THAT HAS BEEN USED SINCE 2004. THERE IS TWO DIFFERENT MODELS THAT HAVE BEEN IN PRODUCTION, THE SERIES 4 & THE SERIES 5.THE SERIES 4HAD WIRES ONLY COMING OUT OF THE BOTTOMOF THE CONTROL. THIS CONTROL IS NO LONGER AVAILABLE & WAS REPLACED WITH THE SERIES 5. THE SERIES 5 HAS TERMINAL SPADES INSTEAD OF WIRES FOR EASE OF REPLACING. WHAT IS REQUIRED FOR CONVERSIONIS A STANDOFF ( P/N 48000)


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Sequence of Operation of Honeywell R7184B Primary Control

1. STANDBY. The burner is idle, waiting for a call for heat. When a call for heat is initiated, there is a 5 second delay while control performs a safe start check.

2. VALVE-ON DELAY. The ignition and motor are turned on for a 15 second valve on delay. During this delay, the blower will circulate air through the heat exchanger, purging what ever fumes that have collected.

3. TRIAL FOR IGNITION (TFI) The fuel valve is opened. A flame should be established within the 15 second lockout time

4. LOCKOUT If flame is not sensed by the end of the TFI, the control shuts down on safety lockout and must be manually reset. If the control locks out three times in a row, the control enters restricted lockout. To reset , hold down reset button for 45 seconds until LED flashes twice.

5. IGNITION CARRYOVER Once flame is established, the ignition remains on for 10 seconds to ensure flame stability before turning off.

6. RUN The burner runs until the call for heat is satisfied. The burner is then shut down and sent to standby.

7. RECYCLE If the flame is lost while the burner is firing, the control shuts down the burner, enters a 60 second recycle delay, and then repeats the above ignition sequence. If flame is lost three times in a row, the control locks out to prevent cycling with repetitious flame loss due to poor combustion.

DISABLE FUNCTION

Any time the motor is running, press and hold the reset button to disable the burner. The burnerwill remain off as long as the button is held and will return to standby when released.

LED INDICATOR KEY

LED STATUS

On Flame sensed

Off Flame not sensed

Flashing ( ½ second on, Lockout/Restricted ½ second off) Lockout

Flashing (2 second on, Recycle 2 second off)


Burner StatesStandby: The burner is idle, waiting for a call for heat. Valve-On Delay: The igniter and motor are on while the control delays turning on

the oil solenoid valve for 45 seconds..

Trial For Ignition: The oil solenoid valve is energized. A flame should be established within the factory set trial for ignition time ("lockout time").

Lockout: The control has shut down for one of the following safety reasons:a. The trial for ignition (lockout) time expired without flame being established.b. The cad cell detected flame at the end of the Valve On Delay state.

To reset the control from lockout click the button 1-second.NOTE: A recurrence of the above failure modes or a failed welded relay check could cause

the control to enter a Hard Lockout state that must be reset only by a qualified service technician. To reset from Hard Lockout, hold the reset button for 15 seconds until the yellow light turns on.

Ignition Carryover: Once flame is established, the igniter remains on to ensure flame stability.

Run: The flame is sustained until the call for heat is satisfied. The burner is then sent to Motor-Off Delay, if applicable, or it is shut down and sent to Standby.

Recycle: If the flame is lost while the burner is firing, the control shuts down the burner,enters a 60 second recycle delay, and repeats the ignition sequence. The control will continue to Recycle each time the flame is lost, until it reaches a pre-set time allotment. The control will then go into Hard Lockout instead of recycle. This feature prevents excessive accumulation of oil in the appliance firing chamber.

Motor-Off Delay: If applicable, the oil solenoid valve is turned off and the control delays turning the motor off for the set motor-off delay time before the control returns to standby.

Pump Prime: The igniter and motor are on with the oil solenoid valve energized for 4 minutes. During Pump Prime mode, the cad cell is disregarded, allowing the technician to prime the pump without having to jumper the cad cell.

Sequence of Operation for Genisys Controller


<3~edett COMMERCIAL

13

2

'1 0

,/

17

fi

'12'

IDF350-II & IDFSOO COMPO~~ E~HS

~~0 . DESCR IPTi m~ PART

1. NOZZLE Ll fl E ASSY. B30258A (IDF350-II & IDF500)

2 AIRTUBE ASSEMBLY B30255A (IDF350-II & IOF500)

3. SPLINE NUT 848267 (IDF350-II & IDFSOD)

4. SUfJTEC "A" PUMP 48139 (IDF350-II & IOF500)

5. COPPER LINE (8") 48152 (IOF350-ll & IDF500)

6. COPPER LINE (11") 48152B (IDF350-ll & IOF500) B30798

7. FUEL SOLENOID VALVE (1DF350-II & IDF50D) 848250

8. BURNER HOUSING-"s" (IDF350-II & IDF50D)

9. PUMP /MOTOR FLEX COUPLING

B48133

(IDF350-ll & IDF500) I 0. AIR GU IDE ( IDF350-11) 830142A

(IDF500) 830142 II . BLOWER WH EEL (IOF350-11) 830141

(IDF500) 830141A 12. BURNER MOTOR (1/3 HP) 48140

(IDF350-II & IDF50D) 13. IGNITOR "S" B48 138A

(1DF350-ll & IDF500)

14. AIR SHUnER 848254 (IDF350-ll & IDF500}

15. AIR BAND (IDF350-II & 848253 IDF50D) .. CAD CELL (IDF350-II & 848154 IDF500)

17. BURfiER MOUfJTING 848252 FLANGE (IDF350-II & IDF500) .. CAD CELL LOCATED UIWER IGNITOR


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IDF350-II & IDF500CF BURNER

ELECTRODE ASSEMBLY(PART #B20268)

NOZZLE LINE / OIL PIPE

BUSS BAR HOLDER

NOZZLE ADAPTERB48150

SOLID NOZZLE2.0-2.5 GPH - (#200)

0

B20262ELECTRODE INSULATOR KIT

INC. BUSS BARS & ELECTRODES

“A” PUMP (#48139) FOR IDF350-II & ALL IDF500

When replacing a fuel pump, ensure 1/16” by pass plug is installed in return port. Use a 5/32” allen wrench.


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ADJUSTABLE FAN SWITCH 90-130’F ( 48111B) ALL MODELS

IDF HIGH LIMITC9648HIGH LIMIT L220 - 40F(48110A)

FEELER IDF(48171)

LIMITS, FAN SWITCHES AND TEMPERATURE FEELERS

Indoor and outdoor settings of fan switch

Indoors & if surrounding air is warm i.e. -5C/23F-Fan switch should be set to 115’ or higher so as to shut down unit when heat exchanger is properly cooled, also keeps fan motor from excessive running on when discharging cooler air.

Outdoor-Fan switch should be set between 100’-90’. The colder the temperature the lower the setting.


HEAT EXCHANGER FOR OIL UNITSP/N 50200-IDF350-II & IDF500 OIL

L

FLUE COLLAR ASSEMBLYP/N 50113-ALL UNITS

COMBUSTION CHAMBERASSEMBLY C/W INNER SHELLP/N 50207-IDF350-II & IDF500

RETAINER BOLT W/WASHER24 PER UNITP/N 48116 ALL UNITS

CAP RING2 PER ASSEMBLYP/N 50115 IDF350-II & IDF 500

OUTER SHELLP/N 50206-IDF350-II & IDF500

HEAT SHIELDP/N 50205 ALL UNITS

*COMBUSTION CHAMBER ASSEMBLY & INNER SHELL ALL ONE PIECE


POWER CORD48163 - #350

48163A - #500

JACKETASSEMBLY(IDF350-II, 500INNER 48204A OUTER 48204B

BURNER MOTOR

48140A-1/4 HP 350/500

MOTOR MOUNT & SCREEN 48803

FAN ENTRY PLATE48175

FLUE COLLARASSEMBLY

50113-#350/#500

HIGH LIMIT/FAN SWITCH COVER48112A

FRONT / SMALL COVER PANEL ASSEMBLY

(IDF350-II & 500)INNER 48119

OUTER 48119A

CANOPY ASSEMBLYWITH HANDLE

AND RAIN GUARD50108

OHV FROST-FIGHTERIDF350-II & IDF500


FRONT CAPASSEMBLY

48205B 12" X 248205AB 16" X 1

FRONTCAP

COLLAR48182

FUEL CAP48126A-350/500 (PLASTIC)

OUTER SHELLOF HEAT EXCHANGER

50206- #350/ #500

COMBUSTION CHAMBER50207 #350 - #500

WHEEL AND TIRE16“ WHEELS 48124A

CAP RING FOR HEATEXCHANGER

50115 - #350 / #500

CRADLEASSEMBLY

48120A-#350,#500

FUEL TANK ASSEMBLY(with drain plug and filler neck)48125B-#350, 500,48125 # 60020125-#200

IGNITOR B48138A 350/500

FAN MOTOR48101 - #35048202 - #50048202E-#500HS

FAN BLADE50103 - #35030203 - #500

50105 -500HS

IDF FROST-FIGHTER #350-II, #500

COMBUSTIONCHAMBER SEAL 48802

CART FOR POLY TANK50125ET


HEATER PARTS MANUAL

HT1010B PARTS MANUAL

Heater Exterior (A)

Reference Part Number Quantity Description

A1 NMC0000867 1 Engine Exhaust Beauty Ring

A2 P270532 1 Engine Exhaust Rain Cap

A3 30537 1 Electrical Receptacle Cover

A4 NMC0000992 1 Supply Side Duct Attachment

A5 MCL-13RB 2 Red Clearance Light

A6 MCL-13AB 2 Amber Clearance Light

A7 TPFF-022 1 Supply Side Panel

A8 TPFF-021 2 Storage Compartment Door

A9 M171A 2 3/4" Amber LED

A10 MCL-ABK 2 2" Amber LED

A11 140080 1 Jack

A12 18128XL 1 Adjustable Pintle Eye Receiver

A13 Reference 4 Corner Lifting Eye



Heater Exterior (B)


B1 NMC0000864 2 Heater Exhaust Beauty Ring

B2 NMC0960005 2 Flue Pipe Rain Cap

B3 NMC0960004 2 Flue Pipe

B4 2402S-50 4 Door Latch

B5 NMC0090007 3 J-Lock Coupling

B6 TPFF-250 1 Return Side Door

B7 ST235-80-R16BE-S 2 Tire

B8 WH166-60E 2 Wheel

B9 81-931 1 Fuel Fill Cap Housing

B10 MCL-55RBK 2 2" Red LED

B11 M171R 5 3/4" Red LED

B12 439K 1 License Plate Light

B13 STL-23RBK 2 4" Red LED

B14 TPFF-023 1 Rear Door

B15 Reference 1 Center Lifting Eye



Engine Compartment (C)


C1 NMC0000840 1 Placard; Warning; Do not operate in a confined space

C2 NMC0000846 1 Placard; Instruction; Engine Starting Procedures

C3 NMC0000855 1 Placard; Instruction; Using Shore Power

C4 CS6365N 1 Generator Plug

C5 282CSL1504 1 Generator

C6 NMC0000820 1 Generator Mount; Lower Piece

C7 NMC1190001 4 Vibration Isolator

C8 C1.5 T4 1 Engine

C9 NMC0000838 1 Placard; Warning; Do not use starting aids

C10 NMC1180001 1 Oil Drain Hose

C11 NMC0000863 1 Engine Mounting Spacer

C12 150-4142 1 Fuel Filter

C13 296-0888 1 Fuel Filter Primer Base

C14 M045237 1 Engine Muffler

C15 5P-1420 1 Fuel Supply Hose

C16 5P-9770 1 Fuel Return Hose

C17 246-5011 1 Air Filter (Inside Enclosure)

NS 271-5059 1 Indicator (Air Filter Service)

NS NMC0000839 1 Placard; Warning; Fire May Result



Battery Components (D)


D1 8T-2910 2 Battery Hold-Down Wing nuts

D2 NMC0000876 1 Battery Hold-Down

D3 153-5700 1 Battery

D4 58X10 1 Ground Rod

D5 NMC0090011 2 Ground Rod Spring Clip

D6 GRC58 1 Ground Rod Clamp

D7 142-9459 2 Battery Hold-Down Bolts

D8 XTP456R 1 Positive Battery Cable

D9 XTP448BK 1 Negative Battery Cable



Control Panel (E)


E1 F828A & F829A 2 Control Panel Mounts

E2 30090482 1 Control Panel

E3 NMC0000994 1 Control Panel Placard (E-stop)



Accessories (F)


F1 NMC1120004 2 Interior Light

F2 NMC0000841 1 Placard; Caution; Stopping Unit

F3 NMC0000843 1 Placard; Instruction; Heater Maintenance

F4 GSS-6474 UZ 4 Gas Strut

NS NMC0000845 1 Light Mounting Bracket (Burner Compartment)

NS NMC0000875 1 Light Mounting Bracket (Engine Compartment)

*NS – Not shown in picture



Trailer Components (G)


G1 JB10-170 1 7-Pole Junction Box

G2 140080 1 8000 LB Jack

G3 TC67-003 1 Trailer Wire Harness

G4 BA10-150 1 Breakaway Battery Kit

G5 CHA0020324 2 Trailer Chain

G6 18128XL 1 Adjustable Pintle Eye Receiver



Electrical Components (H)


H1 SO 12/3 1 Electrical Outlet Cable

H2 AMP 602572 1 120V, 20A Duplex Receptacle

H3 SO 8/4 1 Generator Cable

H4 SO 12/3 2 Heater Cable

H5 BR24L70RP 1 Breaker Box

H6 BD2020 1 20A Duplex Breaker

H7 BR120 1 20A Breaker

H8 Reference - Breaker for Outlet

H9 Reference - Breaker for Front Heater

H10 Reference - Breaker for Rear Heater



Accessories (I)


I1 NMC0170002 1 Fire Extinguisher and Bracket

I2 NMC1200001 1 Document Protector



Burner Fuel System (J)


J1 NMC0000826 2 Fuel Filter Bracket

J2 NMC0320014 2 Fuel Filter Head

J3 NMC0210015 2 3/8" Hose Barb to 1/4" MNPT Elbow

J4 5P-1442 2 3/8" Fuel Supply/Return Hose

J5 NMC0320013 2 Fuel Filter

J6 48130 2 Fuel Hose (including MNPT elbow)

J7 5D-1026 8 3/8" Hose Clamp

J8 NMC0210014 2 3/8" Hose Barb to 3/8" FNPT Fitting



Placards and Decals (K)

Part Number Quantity Description

NMC0000836 1 Warning: Hot!

NMC0000837 1 Warning: Sharp bends

NMC0000838 1 Warning: Do not use ether

NMC0000839 1 Warning: Fire may Result

NMC0000840 1 Warning: Don't Operate Inside

NMC0000841 1 Caution: To Stop Unit

NMC0000842 1 Danger: Shock hazard

NMC0000843 1 Instruction: Heater Maintenance

NMC0000844 4 Warning: Corner Lifting Eyes

NMC0000846 1 Instruction: Engine Starting Procedures

NMC0000847 1 Instruction: Heater Operation

NMC0000851 1 Warning: Remove Duct Covers

NMC0000852 1 Attention: No. 1 Diesel Fuel Only

NMC0000854 1 Fire Extinguisher Inside

NMC0000855 1 Instruction: Shore Power

NMC0000856 1 Ground Symbol Placard

NMC0000994 1 Control Panel Placard (E-Stop, Canada)

NMC0000853 1 Warning: Emergency Stop

NMC0000975 1 Canadian Compliance Placard

NMC0000976 1 Canadian Tire Info Placard


SCHEMATIC/WIRING

DOCUMENTS


Trailer Harness Wiring Diagram (L)

Control Panel Wiring Diagram (M)

B+ 1B- 2

Fuel 3Start 4

Preheat 5Alt. 6

Hi temp 7Low OP 8

Light 9Remote E stop 10Remote E stop 11

B+ 12

P1 15 AMP

1

5019

17 AC30

13

5

5

10 AMP

15

4

4

2

10 AMP

19

129 HOUR

METER

+-

s

11 18

3316

18

AUTO SHUT-DOWN DEVICE

1 RED----------2 ORANGE----3 RED/BLACK-4 BROWN-----5 BLUE---------6 BLACK-------

LIGHT SWITCH

KEY SWITCH

E-STOP SWITCH

67

8

157

8

ALT.

WATER TEMP

OIL PRESS.

123456

J2 P2

15

37


E-Stop and Air Intake Wiring Diagram (N)

B+ 1B- 2

ALT. (0R) 3RED/BLACK 4

BLACK/ WHITE 5WHITE 6

REMOTE E-STOP 7REMOTE E-STOP 8

REV GUARD

1 +

12 T

O 3

2 2

VD

C2

- N

EG

ATI

VE

3 S

IG. C

OM

.4

SIG

NA

L5

TES

T6 7 8

S500-A5MODULE

1 2 3 4 5 6

30 AMP

BULKHEAD 8PIN DEUTCH

P10

E-STOP SWITCH

BLK

WH

TR

ED

AU

X +

HO

TG

ND

57

57

51

52

53

54

55

56

52

585

8

38


Engine Harness Wiring Diagram (O) F-826A

1 RED2 BLACK3 RED/ BLACK4 WHITE5 ORANGE6 YELLOW7 BLUE8 BROWN9 PURPLE10 NOT USED11 NOT USED12 RED

COOLANT OR TEMP SWITCH

ALTERNATOR CASE GROUND

ALTERNATOR B+

ALTERNATOR D+

BATT + ON STARTER

STARTER SOLENOID

GLOW PLUG RELAY

GLOW PLUG RELAY COIL

OIL PRESSURE SWITCH

FUEL SHUT OFF SOLENOID

B- GROUNDTO BLOCK

J1

WORK LIGHT


FAN MOTOR WIRING DIAGRAM

BALDOR MOTORS

From Unit From Unit

From Unit From Unit

Black

Blue

Orange

Black

White

Yellow

Brown

White

Red

J

2

8

1

3

4

Black

Blue

Orange

Black

White

White

Yellow

Red

1

3

5

2

8

WEG MOTORS

4

5

Black

Blue

Orange

Black

White

Brown

Red

1

3

5

2

8

7

White

Yellow 4

CHECK MOTOR RATING PLATE FOR APPLICABLE WIRING.

WEG MOTORS


14

IDF350-II & 500 WIRING DIAGRAM WITHHONEYWELL CONTROL


GREEN

_L -

GROUN D

IDF 350 & 500 WIRING DIAGRAM WITH GENISYS CONTROL

MALE PLUG / POLARilY ' ( 115V!:_"I60Hz) RI'1/ERSED

Ill R I

/ ' WHITE

START HELPER (OPTIONAL)

BLACK '4AAA; I WHITE 1 vvvvvvv 1

FAN I'M MOTOR

THERMOSTAT

c RED RED r> BLUE WHITE ~

THERMOSTAT 11-lERMOSTAT

BLACK RECEPTICLE

BLACK ' OFF ~ RED I @ MANUAL

WHITE I GREEN

(

_L

-GROUND

15AMP BURNER

FUSE HIGH LIMIT IGNITION CONTROL

(OR BREAKER) SWITCH

BLACK BLACK /'"':)., BLACK WHITE

~~- '<J LIMIT L2

FUEL PUMP TR MOTOR

JUMPER BURNER

ORANGE WHITE MOTOR

~TW

- IGNITON

FLAME ~ YELLOW TRANSFORMER

CAD BLUE WHITE DETECTOR CEll

' ' ' YELLOW 'II~-- ' ' ' IGNITERO

FUEL PUMP SOLENOID

RED L1 VALVE VIOLET WHITE

' /BURNER ON G

/ '


DIAGRAM WITH CHARGER

Electric Brake (Blue)

12-Volt Battery Lead (Black or Red)

BlackWhite

Ground (White)

Blue

Breakaway Box

A,B,C and D

are splices

Note: Wire By Function Only. Color Coding is Not Standard Among Manufacturers.

Cable

Breakaway

Switch

B

CA

D

Blue

DIAGRAM WITHOUT CHARGER

Electric Brake (Blue)

White

Ground (White)

Blue

Breakaway Box

A,B, and C are splices

Note: Wire By Function Only. Color Coding is Not Standard Among Manufacturers.

Cable

Breakaway

Switch

B

C

A

Blue


Que

stio

ns?

Cal

l tol

l fre

e 1-

800-

738-

8713

Bre

ak

aw

ay

Ba

tte

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ha

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r

Ins

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In

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dit

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of

ba

tte

ry p

rio

r to

in

sta

lla

tio

n a

nd

pri

or

to e

ac

h t

rip

.

Rem

ove

Cha

rger

and

Bat

tery

from

the

batte

ry

case

.M

ount

bat

tery

cas

e se

cure

ly to

fram

e, ja

ck

post

or o

ther

sui

tabl

e lo

catio

n on

trai

ler.

Bol

t bre

akaw

ay s

witc

h to

fram

e of

trai

ler o

r ba

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cas

e br

acke

t.C

heck

and

inst

all b

atte

ry a

nd c

harg

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to th

e ba

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cas

e. F

eed

wire

s ou

t the

bac

k, th

en

clos

e th

e to

p.W

ire p

er s

chem

atic

dia

gram

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perly

insu

late

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l con

nect

ions

.Fo

r Tec

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ssis

tanc

e an

d W

arra

nty

Info

rmat

ion

call:

1-8

00-7

86-7

968

Imp

ort

an

t F

ac

ts t

o R

em

em

be

r

Impr

oper

inst

alla

tion

of th

e br

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bat

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w

ill d

estro

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e br

ake

cont

rol.

The

nega

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term

inal

mus

t atta

ch to

gro

und

and

pos

itive

te

rmin

al m

ust a

ttach

to th

e br

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way

sw

itch.

Che

ck y

our b

rake

away

sys

tem

per

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cally

to

insu

re th

at w

iring

and

con

nect

ions

are

sec

ure.

A sh

ort o

r an

open

circ

uit c

an re

sult

in a

no-

brak

e co

nditi

on.

If ex

cess

ive

disc

harg

ing

of th

e br

eaka

way

ba

ttery

occ

urs,

che

ck b

atte

ry a

nd re

char

ge

usin

g a

Hea

vy D

uty

Two

Sta

ge/M

aint

enan

ce

Cha

rger

. If u

sing

a c

omm

erci

al (A

C to

DC

) m

ake

certa

in th

e 12

vol

t cha

rge

is li

mite

d to

1.

2 am

ps o

r les

s.If

the

seco

ndar

y ba

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nee

ds c

harg

ing,

cu

rren

t will

be

draw

n fro

m th

e to

w v

ehic

le's

ba

ttery

at a

nytim

e th

e to

w v

ehic

le is

con

nect

ed

to th

e tra

iler.

The

mos

t cur

rent

whi

ch w

ill b

e dr

awn

is 1

.2 a

mps

.To

onl

y ch

arge

the

brea

kaw

ay b

atte

ry w

hen

vehi

cle

is ru

nnin

g, a

bat

tery

isol

ator

may

be

inst

alle

d in

the

12 v

olt s

uppl

y lin

e (B

LAC

K

wire

for t

ow c

harg

er).

12 V

olt

Seale

d L

ead

-Acid

Batt

ery

To

maxim

ize t

he l

ife o

f th

e b

att

ery

th

e f

oll

ow

ing

co

nd

itio

ns s

ho

uld

be m

et:

Avoi

d ov

er o

r und

erch

arge

. Thi

s is

the

sing

lew

orst

ene

my

of le

ad-a

cid

batte

ries.

Bat

terie

s sh

ould

not

be

stor

ed in

a d

isch

arge

dst

ate

or a

t ele

vate

d am

bien

t tem

pera

ture

s.Av

oid

expo

sing

bat

terie

s to

hea

t! S

ervi

ce li

feis

sho

rtene

d co

nsid

erab

ly a

t am

bien

t abo

ve30

deg

rees

C (8

6 de

gree

s F)

.D

ue to

the

char

acte

ristic

s of

this

bat

tery

, afte

rsi

x to

nin

e m

onth

s of

sto

rage

, the

bat

ter

shou

ld b

e re

char

ged.

Cha

rge

the

batte

ry a

t the

pro

per r

ate.

Cur

rent

shou

ld b

e lim

ited

to 1

.2 a

mps

or l

ess.

Cha

rge

curr

ent a

bove

2.3

am

ps w

ill re

sult

in s

horte

ned

serv

ice

life.

Pro

vide

ade

quat

e ai

r circ

ulat

ion

whe

nch

argi

ng b

atte

ry. D

o no

t cha

rge

batte

ry in

any

othe

r con

tain

er b

esid

es th

e su

pplie

d ba

ttery

box.

Do

not p

lace

bat

terie

s in

clo

se p

roxi

mity

toob

ject

s w

hich

can

pro

duce

spa

rks

or fl

ames

.D

o no

t exp

ose

batte

ry c

ase

to o

rgan

ic s

olve

nts

or a

dhes

ives

.D

o no

t atte

mpt

to d

isas

sem

ble

batte

ries.

Con

tact

with

sul

furic

aci

d m

ay c

ause

har

m.

Fast

en b

atte

ries

tight

ly a

nd m

ake

prov

isio

ns fo

r sho

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bsor

ptio

n if

expo

sure

to s

hock

or v

ibra

tion

is li

kely

.D

o no

t thr

ow b

atte

ries

into

fire

; bat

terie

s so

disp

osed

may

rupt

ure

or e

xplo

de.

12 V

OLT

P/N

102

3 - 4

am

p/hr

- m

ax d

isch

arge

cur

rent

20 h

r. ra

te =

225

mA

P/N

202

3 - 5

am

p/hr

- m

ax d

isch

arge

cur

rent

20 h

r. ra

te =

250

mA

Max

imum

Dis

char

ge C

urre

nt =

40

amps

Max

imum

cha

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curr

ent m

ust b

e lim

ited

to

1.2

amps

P/N

102

3, P

/N 2

023:

Leng

th =

3.5

4" W

idth

= 2

.76"

Hei

ght =

4.1

3"W

eigh

t = 3

.8 lb

sTe

rmin

als:

Fas

ten

Tab

.187

" x .0

32"

Ser

vice

Life

:U

nder

nor

mal

ope

ratin

g co

nditi

ons.

4-5

year

s in

sta

ndby

app

licat

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or 2

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000

char

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cyc

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depe

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on d

epth

of d

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and

rate

of c

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away

Bat

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+-

TRA

ILE

RB

RA

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Bre

akaw

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witc

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BLU

EB

LUETOW VEHICLE

TRAILER

Bra

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WHITE

BLU

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TROUBLE SHOOTING

O.H.V. TROUBLE SHOOTING GUIDE

ALWAYS DOUBLE CHECK FOR SUFFICIENT POWER , GAUGE OF CORD (SEE TOP OF PAGE #3) ANDPROPER FUEL SUPPLY. POWER AND FUEL SUPPLY MUST BE SHUT OFF/DISCONNECTED BEFORE

REMOVING OR REPLACING ANY COMPONENTS ON THE HEATER. 1. Unit is turned on, nothing happens after 5 second safe start.

a. Ensure proper voltage coming in, 115V AC.b. Check for power on both sides of burner fuse. If no power, then check toggle switch. If

power on one side, replace fuse. If power on both sides, go to c.c. Check black wire from primary control. If no power there, remove high limit cover &

check for power on both sides of high limit. If power on one side only, replace high limit.If power on both sides, go to d.

d. Ensure thermostat contacts on primary control ( T and T) are jumpered out.e. Make sure light on primary control is not flashing. If so, push button to reset.f. Check manual reset button on motor and wiring connection to motor. If reset pushed

and power going to motor, nothing is happening, replace burner motor.g. On neutral line ( white wires) make sure all connections are tight and secure, and unit is

properly grounded. With AC voltage tester, check white (neutral lines) for power (one onground, one on neutral). If over 5 volts, check polarity. If polarity correct, check wiresindividually for power to determine leak source, then replace leak source.

h. If power coming into black wire on primary control, but no power out to orange wire,replace primary control.

i. If green light on primary control stays on, check to ensure transformer door is closedproperly as cad cell is detecting light. Check cad cell is working. If light stays on and noobvious areas open, check OHM reading across two yellow wires. If you get a reading,replace cad cell. If you get no OHM reading from cad cell, replace primary control if lightstill on.

2. Burner motor starts but unit will not fire.a. Check for power on blue wire on primary control going to ignitor. If no power there,

replace primary control if powered, go to b.b. Remove electrode assembly and check isolators for cracks or chips in the porcelain.

Make sure electrode setting is proper. For electrode adjustments, please turn to page8.Clean assembly if there is any soot or oil..

c The nozzle should be checked and ensure it is not clogged or blocked. Make sure nozzle is not loose.d. Ensure air shutters are properly set to factory specifications.e. Check for power on violet line on primary control. After pre-purge, if no power sent to

violet line, replace primary control. If power on violet line, remove copper fuel line atelectrode assembly to ensure fuel is coming out. If no fuel there, replace solenoid valve.

f. At the bleeder screw, check for proper out pump pressure ( see maintenance section). Iflow or no pump pressure, go to g

g Check oil filter, oil pick up tube and oil lines to ensure free flow and they are not clogged or dirty.h Check electrical polarity and grounding.

3. Burner fires then locks out.a. Check oil pressure to ensure solenoid valve is opening. Check oil flow system, filter,

pick up tubes and lines.b. The nozzle should be checked to ensure it is clean and emitting a good spray pattern,

as this could affect the cad cell operation.c. Cad cell (flame detector) could be defective. Disconnect yellow cad cell wires from

primary control. Start unit and when it fires, connect jumper across connections onprimary control. If unit continues to run, then check cad cell alignment with burner, cleanface with a soft cloth and ensure no external light is affecting it. With an ohmmeter,check resistance across cad cell leads with machine running and primary control cadcell leads jumpered out. If resistance over 1200 OHMS, cad cell should be replaced. Ifunit locks out with jumper, replace primary control.


O.H.V. TROUBLE SHOOTING GUIDE

3. d. Wires between cad cell and primary control should be checked to see that they are not pinched or crimped..

e. Prime fuel pump by loosening bleeder screw till steady stream of fuel comes out to ensure no air or bubbles in fuel line..f. If unit locks out three times in succession, it will go into restricted lock out mode. To reset, hold down reset button for 45 seconds until LED flashed twice. The unit will then resume in normal operating mode. After verifying primary control is not in lockout & light continues to flash, replace primary control.g. Check polarity, ground & voltage must be between 108-132v AC.h. Make sure high limit is functioning properly.

4. Smoky firea. Check nozzle, make sure is tight and not clogged.b. Check combustion chamber for cracks or burnt out. c. Check air band settings. (Air shutter and/or air band may be closed too much-restricting combustion air.d. Check pump pressure.e. Check slide plate to make sure it is in correct position.( See page 8 for settings)If necessary, open slightly.

5. Delayed ignitiona. Check for proper electrode setting. b. Check the isolators for cracks or a conducting coat of soot or oil. Cracks sometimes occur under the electrode bracket, causing a short circuit.c. Check to see that the air shutter is not overly open-too much air will blow out flame.d. Check to ensure pump pressure is properly set..e. Change nozzle.f. Check fuel filter, replace if necessary.g. Ensure that draft or wind is not blowing out flame-add 3’ stack.

6. Main fan will not come on, unit shuts down on high limit..a. Check temperature feeler, make sure it is in properly.b. Jumper out fan switch to test motor. If you have voltage to motor and still does not start, replace motor. Check line voltage to ensure proper voltage. Also checks amp draw on motor, motor may be running too hot and not run due to thermal overload being tripped.c. Replace fan switch if you have power on one side after unit heating up it does not make.d. Replace high limit as it may be tripping too soon and not giving fan switch time to engage.e. Ensure fan switch temperature is correct for weather conditions ( see page 7 for settings)

7 Unit on, but cycles on high limita. Check air flow, ensure both ducts are in place and clear of obstruction and straight.b. Check pump pressure, unit could be over firing.c. Check nozzle that proper size of nozzle is installed.d. Change high limit.e. Maximum duct length with 2 X 12” outlet is 24’ on each side. 1 X 16” outlet , length is 45’. Any longer will create back pressure in the unit and trip the high limit.* SEE PAGE 2 FOR SPECS*

8 Combustion chamber turns red.a. Nozzle may be firing side ways (replace or adjust)b. Clogged nozzle ( replace)c. Temperature feeler not on properly or missing ( Must be touching heat exchanger)d. High limit not functioning ( replace)e. Excessive pump pressure. Check and reset if necessary.


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