Service manual

— Page 71 —
© January 2013 Aqua-Hot
®
600-D01 Series Hydronic Heating System Service Manual - Rev. A
SECTION 9: DIESEL-BURNER COMPONENTS
Motor Replacement Procedure:
1
. Follow the directions for detaching the diesel burner
in section 8.
2.
Remove the four ignition coil screws that secure the
ignition coil to the protection cap. Lift the ignition
coil to disconnect its wires from the C-plug harness
wires prior to removing. Remove the protection cap
from the diesel-burner so that the motor clutch
halves are exposed.
3.
Remove the three hex head screws that secure the
motor and flange assembly to the blower housing.
Remove the motor and flange assembly along with
the clutch halves. Disconnect the motor’s black (+)
and brown (-) wires from the C-plug harness’ wires.
4.
Detach the motor from the motor flange by removing
the two Phillips heads screws that fasten the two
parts together.
5.
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.
This will ensure a proper protection cap fit.
6.
Reinstall a clutch half on both the new motor’s shaft
and the combustion air blower shaft. Attach the mo-
tor and flange assembly, with the recessed edge of
the motor flange in-line with the wiring access slot of
the blower casing, to the blower housing with the
three hex head screws.
7.
Connect the black (+) and the brown (-) wires of the
new motor to the C-Plug harness’ Black (+) and
brown (-) wires. Feed the C-plug harness’ yellow
and brown wires back through wiring access hole in
the protection cap.
8.
Reinstall the protection cap. Reconnect the ignition
coil wires black (+) to yellow (+) and brown (-) to
brown (-) wires.
9.
Reinstall the ignition coil and secure to the protection
cap with the four ignition coil screws.
10
. Follow the directions for reattaching the diesel
burner in section 8.
11.
Test for proper operation
Be sure to move the Diesel-Burner switch on the In-
terior Switch Panel to the OFF position and discon-
nect the Diesel-Burner’s power supply before de-
taching the Diesel-Burner from the Aqua-Hot. Fail-
ure to turn off the Diesel-Burner and disconnect
power could result in serious bodily injury.
NOTE:
Inspect the clutch halves for cracks and also en-
sure that the flat portion in each shaft hole is free of wear
and tear. Too much play on the shaft produces a loud clack-
ing noise. If any cracks or wear are detected, the clutch half
must be replaced.
NOTE:
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.
NOTE:
Inspect the blower casing’s O-ring for damage or
wear prior to reinstalling the diesel-burner head’s protection
cap. If damage or wear exists, replace the O-ring.