Aqua-Hot Hydronic Heating System Shop Manual 09/04
®
SECTION 8: DIESEL-BURNER SERVICE, MAINTENANCE, AND REPAIR INFORMATION
Motor,
continued
Replacement Procedure:
1.
Remove the four
Ignition Coil Mounting Screws
, which secure the
Ignition Coil
to
the
Protection Housing
; reference Figure 13. Lift the
Ignition Coil
to disconnect
its wires from the C-Plug Harness
wires
prior to removing. Remove the
Protection Housing
from the
Diesel-Burner
to expose the
Motor
and
Clutch
Halves
; reference Figures 13 and 14.
2.
Remove the three
Hex Head Screws,
which secure the
Motor
and flange assem-
bly to the
Blower Housing
; reference Figure 13. Remove the
Motor
and flange
assembly along with the
Clutch Halves
; reference Figures 13 and 14. Discon-
nect the Motor’s
Black (+)
and
Brown (-)
wires from the C-Plug Harness’
wires
;
reference Figure 13.
NOTE:
Inspect the
Clutch Halves
for cracks and ensure that the flat portion in
each shaft hole is free of wear and tear. Too much play on the shaft
produces a loud clacking noise. If any cracks or wear are detected, the
Clutch Half
must be replaced. Reference the Aqua-Hot’s “Parts Manual”
for spare parts information.
3.
Detach the
Motor
from the
Motor Flange
by removing the two
Phillips Head
Screws
, which fasten the two parts together; reference Figure 13.
NOTES:
A:
Be sure to test the Diesel-Burner’s
Bearings
prior to reinstalling the
Motor
. Worn
Bearings
can cause lower than normal RPM readings and
premature
Motor
wear. To properly test for worn
Bearings
, reference
Section 8.9 for the Bearings “Function Test.”
B:
The
Motor
must be mounted to the flange with the
wires
and drain hole
pointing downward and the recessed edge of the
Motor Flange
pointing
upward; reference Figure 14. This will ensure a proper
Protection
Housing
fit.
4.
Reinstall a
Clutch Half
on both the new Motor’s shaft and the Combustion Air
Blower’s shaft. Attach the
Motor
and the flange assembly, with the recessed
edge of the
Motor Flange
in-line with the Wiring Access Slot of the
Blower Cast-
ing
, to the
Blower Housing
with the three
Hex Head Screws
; reference Figure 14.
NOTE:
Inspect the Blower Casing’s
O-Ring
for damage or wear prior to reinstall-
ing the Diesel-Burner Head’s
Protection Housing
; reference Figure 14.
If damage or wear exists, replace the
O-Ring
. Reference the Aqua-Hot’s
“Parts Manual” for spare parts information.
5.
Connect the
Black (+)
and
Brown (-)
wires of the new
Motor
to the C-Plug
Harness’
Black (+)
and
Brown (-)
wires; reference Figure 13. Feed the C-Plug
Harness’
Yellow
and
Brown
wires back through the
Wiring Access
Hole
in the
Protection Housing
; reference Figure 13.
6.
Reinstall the
Protection Housing
. Reconnect the
Black (+)
and
Brown (-)
wires
of the
Ignition Coil
to the C-Plug Harness’
Yellow (+)
and
Brown (-)
wires; refer-
ence Figure 24. Reinstall the
Ignition Coil
and secure to the
Protection Housing
with the four
Ignition Coil Mounting Screws
; reference Figure 13.
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