BENSON LD7 1LP Troubleshooting guide

PORTABLE HEATER PARTS LIST AND SERVICE MANUAL
BENSON HEATING LTD

INTRODUCTION
The C.S.H heater is designed and manufactured within
the quality guidelines
of ISO 9001
Care should be taken to ensure that the information used
from this manual is applicable to the model
of heater.
This manual provides the necessary information for the
safe operation, cleaning, and servicing
of the C.S.H.
Heater.
Whilst every care
is taken to ensure that the information
in this manual is correct Benson Heating accept no
liabilityfor misuse orfrom any loss, damage, orinjury
caused by errors in, oromissions from the information
supplied.
HEALTH AND SAFETY AT WORK ACT 1974
Undersection 6
of the Health &Safety at work act 1974
the manufacturer has taken reasonable and practical
steps to ensure that the Benson range
of appliances are
safe and without risk when properly used.
These Heaters should therefore only be used in the
manner and purpose for which they were intended and in
accordance with the recommendations detailed herewith.
The Heaters have been designed, manufactured,
assembled, and inspected with safety in mind, there are
certain basic precautions which the user should be aware
of and the user is therefore strongly advised to read the
operating instructions before operating the Heater
Contained within the text
of this manual the words
CAUTION and WARNING are used to highlight certain
points.
CAUTION
Is used when failure to adhere to the
instruction could result
In premature failure ordamage to
the heater.
WARNING
is used when failure to heed or implement the
instruction can lead to component damage orrisk
of
personal injury.
IPAGE No2
SAFETY INFORMATION FOR HEATER
OPERATION
This equipment should only be used by acompetent
person who has read and understood the following
instructions
Do not use this equipment if you are ill feeling tired
or under the influence of alcohol or drugs.
WARNING
Keep animals and children awayfrom heater NEVER
leave them alone when heater is in use
Never use the heater ifhighly flammable vapours are
present,
or in a dUSty environment.
Never stack or lean objects on oragainst the heater
whilst in operation
Never restrict the air supply to the heater
Ensure the operating area is well ventilated restricted
combustion can cause carbon monoxide-concentrated
carbon monoxide kills
Never Operate the heater near vehicle exhaust fumes
Never fill the heaterwhilst it is hot or running
Always wear protective ciothing when filling heater
(Gloves Goggles etc)
Never smoke orallow naked light into the area when
refueling
Always mop up any spillage immediately
Never breathe any unbumtgas oil vapours
Always ensure heateris standing on afirm level non-
combustible surface
Never move the heaterwhilst itis in operation
WARNING Before carrying out any work on the heater
ensure that electrical supply is isolated 110 Volt heaters
piug into astandard 110 volt generator ensure flex and
plugs are undamaged. Uncoil extension leads fully
Never run leads through water orover sharp objects
Never carry or pUll heater by the electrical cable
WARNING use
of electrical equipment in damp orwet
conditions can be dangerous
Ensure that the sections on Heater Controls and
Heater Operation are read and understood before
operation of this equipment.
Forfurther information contact and advice contact
Spares IService Depts. at Knighton Powys
TELEPHONE [phone] FAX [phone]

~ECHNICAL SPECIFICATION
CONFINED SPACE HEATER.
(DIESEL)
Heat Output
Air Delivery (cold)
Temperature Rise through Unit
Nozzle size
Pump Pressure (Diesel)
Max Fuel Throughput
Sound Level (D.b.a.)
Electricity Supply
Motorsize
Start current
Run current
Weight
FuelType
Tank Capacity
11 Kw
(37,500Btu)
@7mtrs 0.202m3
/s
@14mtrs 0.185 m
@7mtrs 40°C
@14mtrs 30°C
Danfoss 0.30 Usg x60°H
90 Psi
1.3ltrs/hr
70 D.b.a.
11 OVolt 150Hz
2550 Rpm
220 Watts
4.5
Amp
2.0 Amp
48 Kgs
Diesel
16
Us
PAGE No 3I

PAGE No 2
PARTS LIST
1 2 3
4
1A
13
14
15
16
5
6
7
89
10
11
1917
17A 18
20
21
22
23
2425
26
27
12
28
29
30
31
32
31A
33
35
36
34
37
38
39 40
41
42
43
43A
44
45
30

PAGE No 3
PARTS LIST
Item No Parts Description No Off Part No
1 Topcoveroutercasing 1 21-30-011
2 FluePipe assembly 1 21-30-057
3 Burnercover 1
4 Pressureswitch 1 E8010810000100
5 Photocell 1 E8010610000000
6 Allenscrews-hexagonhead 2 E8040017320000
7 Burnerassemblyincludingbase 1
8 Electrodeassembly 1 E8020003000001
9 Blasttube 1 E8000400100400
10 Blasttubemountingcollar 1 E8000100500101
11 BurnerGasket 1 21-30-061
12 Nozzle 1
13 Heatexchanger 1 21-30-001
14 Heatshieldassembly 1
15 Thermostat 1 28-16-049
16 Thermostat-resettype 1 28-16-050
17 Inlet valvesolenoidassembly 1 E80010403110300
18 Quickreleasevalve 1 E8030120220200
19 Filterbowlcompletewithfiltercartridge 1 E9030310110100
19A Filtercartridge 1
20 Elbow 3 E8030010420100
21 Fuelpump 1
22 Quickreleasevalve 1 E8030110430100
23 Ignitionunit 1 E8010203210000
24 Fancoverassembly 1 21-30-012
25 ControlBox 1 E8010511003500
26 Fanandmotor 1 28-09-070
27 Capacitor 1
28 Outercoverbasepanel 1 21-30-010
29 Outletspigotassembly 1 21-30-022
30 3corecable110Volt Yellow 1 28-02-184
31 Thermostat 1 28-16-047
32 Thermostatmountingplate 1 21-30-030
33 Neon-Yellow 1 28-50-022
34 Neon-Green 1 28-50-021
35 Neon-Red 1 28-50-020
36 SwitchON/OFF 1 28-40-127
37 Base cover-outerpowerinlet 1 21-30-032
38 Basemountingframe 1 21-30-023
39 BurnercasingLowerpanel 1 21-30-024
40 Baseblankingpanel 1 21-30-031
41 Frontcover-Lowerinner 1
42 110Volt3pinconnectionplug-transformer 1 28-06-044
43 110Volt3pinconnectionplug -heater 1 28-06-039
43A 110Volt 3 pin socket- heater 1 28-06-035
44 Terryclip-Airducting 1 28-01-079
45 Airducting-Flexible 1 28-01-077

PAGE No 4
PARTS LIST
5
6
8
7
3
4
4A
2
1

PAGE No 5
PARTS LIST
Item No Parts Description No Off Part No
1 Fuelpipes 2 28-08-009
2 FuelElbows 2 29-00-258
3 Fueltank 1 21-30-071
4 Heatermounts 2 21-30-070
5 Frame 1 21-30-045
6 Spindle 1 21-30-067
7 Lockingdome-wheel 2 A30-01-030
8 Wheel 2 A30-01-002

IINSTALLATION AND CONTROLS
1MOBILE HEATERS FUEL SUPPLY
All Mobile Heaters are setto operate on atwo-pipe
system.
In order to promote trouble free operation it is
necessary that the oil does not fall below the cold
filter plugging point with class D fuel this is -4°C
Summer grade and -12°C Winter grade
All pipe work and fittings must be sealed so as to prevent
the ingress
of air.
ELECTRICAL SUPPLY
110 Volt electrical supply connection is made to the
heatervia the generator
THERMOSTAT CONNECTION
Atemperature control thermostat located within the
heater air discharge spigot can be adjusted to the
required temperature via the dial located on the heater
control panel.
FLUE INSTALLATION
C.S.H. Mobile Heaters are dispatched with the requisite
stack spigot and flue pipe.
It
is recommended that O.5mm stainless steel flue be
fitted
In general each indirect heater should have its own flue,
which should terminate approximately 500mm above the
heater.
When siting the heaterand flue the proximity
of other
buildings and obstacles should be considered.
FLEXIBLE DUCTING
IMPORTANTThe flexible ducting supplied with the
heatershould be fitted with the direction
of flow which is
indicated by an arrow on the duct pointing awayfrom the
heater
It should be secured to the outlet spigot with the pull strap
provided.
I PAGENoB
HEATER CONTROLS
1. THREE POSITION SWITCH ( HEAT IOFFI VENT)
110 Volt supply indicated by a green Neon light on
panel
(Heat position) Operates the bumercontrol circuit to the
control box
(Offposition) Breaks the
bumer control circuit to the
control box
(Vent position) operates the fan only for ventilation
purposes
2. THERMOSTAT CONTROL KNOB
Enables the temperature in the air ducting to be regulated
to the desired temperature. The
orange neon light on the
panel (bumerrun
light) will be on until the desired
temperature is reached and the burner switches off.
3. CONTROL BOX
Situated on the control panel, monitors the combustion
process
of the heaterto ensure that all components are
operating correctly, it will shut down the heater ifafault
occurs, ared light showing
in the center of the Satronic
Control Box will flash periodically as the box monitors the
burneroperation
Ifthis light is permanently on it indicates that there is a
fault with the operation
of the bumerand it has gone to
lockoutthe red button should be pressed (LOCKOUT
RESET)
See fault-finding chart
in bumer manual.
4. OVERHEAT THERMOSTAT
Located on the heat shield
is asafety overheat
thermostat, this thermostat will operate ifthe combustion
chamber becomes to hot
in the event of afan failure or
restricted airflow.
The thermostat when it operates will immediately shut
down the bumer and ared ** neon light will be
illuminated on the control panel.
The thermostat can be reset by pushing the plastic reset
button located on the top
cover, the red** neon will go
out when
reset.
IT MUST BE MANUALLY RESET AND THE CAUSE OF
THE
OVERHEAT SHOULD BE INVESTIGATED
The above red ** neon is dual purpose see
also operating instructions.

~PERATING INSTRUCTIONS
The heater should be positioned
on firm ground ensuring
that the airintake is clear ofvehicle exhaust fumes and
other hazardous conditions:
Connect the 110 Volt supply cable from the generatorto
the heater.
The
green neon will be illuminated.
Ensure fuel supply
is clean.
Connectthe ducting to the duct spigot on the heater
using pull strap provided ensuring the correct direction
of
flow
Fit the flue pipe to the top
of the heater
The heater is now ready for use
To VENT only, putthree position switch to vent position,
the fan only will operate
To HEAT, put three position switch
in heat position
The main fan will run and the red** neon on the controi
panel will illuminate indicating that the pre heaterfitted to
the burner is operating and pre heating the fuel priorto
the burner start .
NOTE
the red** neon will indicate pre heat at initial
start up only, if the neon is illuminated at any other
time the heater is at overheat.
After approximately 150 seconds the
red" neon will go
out and the bumerwill fire, the
orange neon on the
control panel will illuminate.
The heaterwill now operate controlled by the thermostat.
To STOP put three position switch to off position.
The burner ON
orange neon will go off, and the main fan
will continue to run for afurther 5minutes to sufficiently
cool the combustion chamber the fan will then switch
off .
Only then rnay the electrical supply be safely
disconnected.
WARNING
Failure to cool the heater sufficiently will cause damage to
the combustion chamber and lead to nuisance overheat
lockout problems.
COMMISSIONING PROCEDURE
1Ensure heater has fuel supply.
2Ensure thermostat is at desired ternperature
3Connect electrical supply
4Switch to heat position
5Ensure lockout button
on control box is reset, burner
sequence should start immediately
6Run heaterfor approx.15 minutes
7Switch heaterto OFF check operation
of overrun
thermostat
8Restart heaterto check correct operation
of thermostat
MAINTENANCE INSTRUCTIONS
WARNING
Before carrying out any maintenance work
on the heater
ensure that electrical supply is isolated and fuel supply
disconnected.
FUEL SYSTEM
FILTERS
All heaters are supplied with afilter located
in the fuel line
the paper filter cartridge cannot be cleaned and must be
totally replaced during servicing orwhen contaminated,
FUEL PUMP PRESSURE ADJUSTMENT
Ensure electrical supply
is offand disconnected.
Remove rear lower base coveron heater
Remove vent plug located on the end
of the brass
extension pipe on the pump body (in the center when
viewed from rear
of heater)
Fit pressure gauge to brass extension
Re connect electrical supply
Switch BurnerON observe reading on gauge
Setpressure to (90 psi) diesel only
Ifadjustment is required situated above the fuel inlet
connection (left side when viewed from rear) is ascrew
and locknut undo the locknut insert
PhiJlips screw driver
into the screw head adjuster, turn clockwise to increase
anticlockwise to decrease the pressure.
When the pressure is correctly set tighten locknut
disconnect the electrical supply, remove gauge and
replace bleed screw and ensure it is tightly located
Replace rear cover
PAGE Nog I

[MAINTENANCE
BURNER MAINTENANCE
Burner Maintenance should only be carried out by
competent personnel
and will require the complete rernoval
of the Burnerfrom
the combustion chamber
BURNERASSEMBLY
see pages 15 &16 for further detail
Disconnect the electrical supply to the heater
Disconnectfuel supply
Carefully roll heater on
to its side and remove the 4xM5
Screws from the base return unit to upright position
Remove top cover of heater 6 X M5 Screws
Remove bottom rear panel 4 x M5 Screws
Remove fan assernbly Screws 4 X M5 (lower two can be
accessed by inserting screw driverthrough the holes in
the base
of the heater)
and liftfan assembly out
Disconnect the wires from the block at the rear
of the
burner head
Remove the thermostat capillary from the securing clips
in nose cone and lowerinto the heater base through the
hole provided.
Remove the blanking panel 4 X M5 Screws
Rernove the two screws securing the burnerto the
combustion chamberflange
The burner, blast tube, and control base can now be
cornpletely removed through the rear
of the heater.
Maintenance
of the Burner is detailed in the Installation
and Service Manual supplied separately.
Clean soot
or carbon deposits from diffuser, end ring, or
electrode tips
Clean and inspect electrodes for cracks replace if
necessary
Reset electrodes to dimensions shown in Burner manual
do not overtighten securing screw
Anew Nozzle should be fitted every 12months
or if
existing nozzle
is damaged or worn.
Reassemble taking care that all parts are clean and dry.
Ensure fuel pipe
is kept free from dirtwhilst burner head
is dismantled
IPAGE No 10
PHOTOCELL
Ensure that the photocell is clean (wipe clean with asoft
cloth)
CONTROL BOX
The control box cannot be repaired ifthe box is faulty it
should be replaced with anew box
WARNING
The control box should not be reset more than twice
before the fault is located and corrected,
or any
surplus oil emitted into the chamber has been
mopped out through the burner entrance.
HEAT EXCHANGER REMOVAL
Remove complete burner assernbly
Ifrequired the combustion chamber can be removed by
bending up the chamber retaining clips and sliding the
chambertowards the rear
of the heater
Chamber can now
be cleaned by tapping the outside of
the chamber with ahide hammer or piece of wood. Care
should be taken notto damage the burner flange.
Rernove any loose soot, carbon through the draught tube
aperture
or the flue stack spigot
Re assemble
in reverse order of above instruction.

IFAULT FINDING
Fault Cause Remedy
(a) No Electricity Supply Check Supply
Heater Fails
to start when heat is
Fan runs supply correct
switched
ON
(b) Switch fan to manual Check thennostat
Thermostat calling for heat
(c) Faulty Thermostat Reset
red button on trip,
(d) Overheat thermostat tripped Investigate cause
Red light showing on satronic (a) No fuel Check fuel
(b) Air lock
in fuel supply Bleed Fuel system
control box (c) Photocell not detecting Check &clean Photocell
flame
(d) Faulty electrodes Check electrode for cracks, check
(e) Faulty control box ignition leads
(afPhotocell notaetecting
~heck photocell
Heaterruns for short period does flame
hot light control box goes to lockout (b) No fuel
bheck fuel supply
(c) Ignition failure
bheck ignition leads
bheck electrodes are clean &gap
~et correctly
(d) Fuel pump failure
~heck solenoid valve
(e) Faulty solenoid valve
bheck electrical connection to valve
Red neon light on fan not working (a) Heater gone to overheat Reset overheat thermostat
(a) Photocell not detecting light
~heck photocell operation
Heater attempts to light up but (b) Faulty photocell connection
/:heck wiring connection
in control box
Burner Control box goes to lockout (c) Faulty control box
bhange control box
(d) Air pressure switch not
bheck switch
bperating solenoid
(a) Air control incorrectly set Reset aircontrol
Heater runs but emits black smoke (b) Nozzle loose or incorrect Check nozzle
rom stack box (c) Incorrectfuel pressure Check fuel pressure
(d) Exhaust stack restricted Clear stack
(e) Excess carbon in the Clean carbon from draught tUbe
~raught tube
Heaterruns butfan overrun does (a) Loose wire on the overrun
hot work when switched off****** Checkwiring
norder to check this fault the device
lleater should be run to ensure the (b) Overrun device faulty Replace overrun device
k;ombustion chamber is hot enough
(a) Air
in the fuel supply Check fuel pipe for cracks, check
pipe unions are tight
Heater runs but flame is intermitten (b) Heater running out
of fuel Checkfuel supply
(c) Filter blocked Clean filter
(d) Dirty nozzle Check nozzle
PAGENo11

KEY·
X1
•
SATRONIC
DK0972
BASE
SW
•
SELECTOR
SWITCH
(HEAT/OFFNEND
M1
•
BURNER
MOTOR
M2
•
AIR
CIRCULATOR
MOTOR
(FAN)
L1 •
OVER
HEAT/STAND
BY
NEON
(RED)
L2
•
BURNER
RUN
(ORANGE)
L3
•
POWER
ON
(GREEN)
V1
•
OIL
VALVE
P
·OILPUMP
PH
•
OIL
PRE·HEATER
TS
•
THERMOSTAT
PT
•
PHOTOCELL
T •
IGNITION
TRANSFORMER
PA
•
AIR
PRESSURE
SWITCH
TSO
•
OVERHEAT
THERMOSTAT
cJw
RESET
TSR
•
RUN·ON
THERMOSTAT
LK1
•
BURNER
LINK
MIS
•
MAINS
INLET
SOCKET
M1
w
1---'7""'H-r-;H>-J
zl--....J
X1
r-----------------------r,~~~~;rL~r,~~~
t
M2
•
L-----------------------~_,L~~~~~L;J_,L~~
"
:E
~
L1
G')
~
mZ
Z
0G)
....
C
I\)
»
MAINS
G)
INLET
~
110V·50Hz
3:

PAGE No 6
NOTE:
FOR ALL SERVICE PROCEDURES EXCEPT
PRESSURE TESTING THE HEATER MUST BE
REMOVED FROM THE TRANSPORT CRADLE.
REMOVE THE 4 PHILIPS HEAD SCREWS
HOLDING THE HEATER TO THE CRADLE.
SERVICE MANUAL
1 TO REPLACE THE FAN UNIT AND/OR
CAPACITOR AND/OR TEMPERATURE
CONTROL THERMOSTATS
1:1 BEFORE REMOVING THE HEATER FROM THE
TRANSPORT CRADLE REMOVE THE LOWER
REAR COVERS (FIG. 2), BY REMOVING THE 4
ALLEN SCREWS ON THE OUTER COVER TO
GAIN ACCESS TO THE FUEL SUPPLY AND
RETURN PIPES, AND UNCLIP THE PIPES (FIG.
3), AND CAREFULLY FEED THEM THROUGH
THE CASING.
FIG. 2
FIG. 3
FIG. 1
4 PHILIPS HEAD
SCREWS
UNCLIP THE FUEL PIPES AND FEED
THEM THROUGH THE CASING

PAGE No 7
1:2 REMOVE THE FLUE COVER (FIG. 4) BY
LIFTING OVER THE FLUE
1:3 REMOVE THE TOP COVER (FIG. 4), BY
REMOVING THE 4 ALLEN SCREWS
FIG. 4
FIG. 5
1:4 TO REMOVE/REPLACE THE CAPACITOR,
REMOVE ITS LOCATION NUT, AND WIRING
FROM THE TERMINAL BLOCK.
REPLACE WITH A NEW UNIT AND CONNECT
ALL WIRING, AND REPLACE ALL COVERS.
UNSCREW THE
RETAINING NUT
AND WIRING FROM
THE TERMINAL
BLOCK
FIG. 6
1:5 TO REMOVE/REPLACE THE THERMOSTATS,
REMOVE THE LOCATION SCREWS, AND
SPADE CONNECTORS, AND REMOVE THE
THERMOSTATS (FIG. 6).
REPLACE WITH A NEW UNITS AND CONNECT
ALL WIRING, AND REPLACE ALL COVERS.
UNSCREW THE
RETAINING
SCREWS AND
REMOVE THE
SPADE TERMINALS
SERVICE MANUAL

PAGE No 8
1:7 PLACE THE HEATER IN ITS NORMAL
POSITION AND REMOVE THE REMAINING 2
ALLEN SCREW (FIG. 8)
1:8 UNPLUG THE MULTI WAY CONNECTOR AND
THE 4 THERMOSTAT LEADS (2 ORANGE 2
YELLOW)
1:9 UNPLUG THE PHOTOCELL (FIG. 9)
1:10CAREFULLY REMOVE THE FAN AND COVER
(FIG. 10) ASSEMBLY FROM THE CASING, AND
THEN REMOVE THE FAN FROM THE REAR
SLOTTED COVER BY REMOVING THE 4
ALLEN SCREWS.
1:11REPLACE WITH A NEW UNIT.
1:12RE ASSEMBLE BY REVERSING THE STRIP
DOWN PROCEDURE
(NOTE WHEN REPLACING THE PHOTOCELL
UNIT- IT ONLY FITS ONE WAY, DO NOT USE
EXCESSIVE FORCE WHEN REPLACING - IT
COULD BE DAMAGED)
SERVICE MANUAL
FIG. 8
FIG. 9
FIG. 10
1:6 TIP THE HEATER ON ITS SIDE TO EXPOSE
THE 2 LOWER FAN RETAINING SCREWS, AND
REMOVE THE TWO SCREWS (FIG. 7)
FIG. 7

PAGE No 9
SERVICE MANUAL
FOLLOW THE PROCEDURE FOR REMOVING THE
FAN (1:1 TO 1:9)
2:1 ROTATE THE HEATER ON TO ITS SIDE AND
REMOVE THE 4 ALLEN SCREW HOLDING THE
BURNER TRAY ASSEMBLY INTO POSITION
(FIG. 11).
2:2 REMOVE THE 2 LONG ALLEN SCREWS
HOLDING THE BURNER ON TO THE HEAT
EXCHANGER (FIG. 12).
2 TO REPLACE THE INJECTOR
2:3 REMOVE THE ‘P’ CLIP FROM THE GUARD,
AND REMOVE THE CAPILARY TUBE.
FROM THE CASING (FIG. 13), AND
CAREFULLY SLIDE THE COMPLETE BURNER
TRAY ASSEMBLY OUT OF THE BOTTOM
TRAY.
WHEN THE TRAY IS REMOVED THIS GIVES
ACCESS TO ALL OTHER SERVICEABLE ITEMS
(FIG. 13)
FIG. 11
REMOVE 4 SCREWS
FROM CASING
UNDERSIDE
FIG. 13
REMOVE THE
‘P’ CLIP
FIG. 12

PAGE No 10
FOLLOW STEPS FOR REMOVING THE FAN AND
INJECTOR
3:1 REMOVE THE BURNER COVER, BY
UNSCREWING THE 4 ALLEN SCREWS (FIG.
14)
3:2 REMOVE THE COVER RING (A), BY
UNSCREWING THE SINGLE BUTTON HEAD
ALLEN SCREW (FIG. 15), TO GAIN ACCESS TO
THE INJECTOR.
3:3 UNCLIP THE IGNITION LEADS AND REMOVE
THE ALLEN SCREW, AND REMOVE AND
REPLACE THE ELECTRODE ASSEMBLY.
4 TO REPLACE THE IGNITION UNIT
FOLLOW STEPS FOR REMOVING THE
INJECTOR
4:1 UNPLUG THE IGNITION LEADS (FIG. 16)
4:2 REMOVE THE 2 ALLEN SCREWS AND
REPLACE WITH A NEW UNIT
3 TO REPLACE THE IGNITION ELECTRODES
SERVICE MANUAL
2:3 REMOVE THE 3 SCREWS HOLDING THE
BLAST TUBE IN POSITION. (FIG. 14)
NOTE: THE BURNER TRAY PRESSING IS
SHOWN CUT AWAY FOR CLARITY
2:4 REMOVE THE INJECTOR, USING A 16MM
LOCK SPANNER AND A 14MM SPANNER.
CARE MUST BE TAKEN NOT TO DAMAGE THE
IGNITION ELECTRODES WHEN
REMOVINGANDREPLACING THE INJECTOR.
REPLACEMENTIS THEREVERSAL OF
REMOVAL
BLAST RING
& 3
RETAINING
SCREWS
INJECTOR 14MM
LOCK
SPANNER
FLATS
FIG. 14
COVER RING
& ALLEN
SCREW
BURNER
COVER
BLAST
RING
ELECTRODE ASSY.
& ALLEN SCREW IGNIGNITION LEADS
FIG. 15
IGNITION
LEADS ALLEN
SCREWS
FIG. 16

PAGE No 11
6 TO REPLACE THE THERMOSTAT, NEONS AND
ON/OFF SWITCH
FOLLOW STEPS FOR REMOVING CONTROL
BOX
6:1 TO REMOVE THE THERMOSTAT, REMOVE
THE CONTROL KNOB, AND UNSCREW THE 2
RETAINING SCREWS. REPLACE WITH A NEW
UNIT, AND REFIT ALL ITEMS (FIG. 18).
6:2 TO REMOVE AND REPLACE A NEON.
UNSCREW YTHE LEADS AT THE CONNECTOR
BLOCK (THEY ARE FLYING LEADS), NOTING
THEIR TERMINAL NUMBERS.
UNSCREW THE RETAINING NUT, WITHDRAW
THE NEON, AND REPLACE.
6:3 TO REPLACE THE ON/OFF SWITCH.
UNPLUG ALL WIRES FROM THE SWITCH,
NOTINGTHEIR TERMINALNUMBERS, UNCLIP
THE SWITCH, AND FIT A REPLACEMENT.
REFIT ALL WIRES, AND OTHER COMPONENTS.
7 TO REPLACE THE POWER INPUT SOCKET
FOLLOW STEPS FOR REMOVING CONTROL
BOX
7:1 TO REMOVE THE POWER INPUT SOCKET,
NSCREW THE 3 POWER RING TERMINALS/
WIRES FROM THE SOCKET, AND THEN
UNSCREW THE 4 NUTS HOLDING THE
SOCKET IN PLACE (FIG. 19).
REPLACE WITH A NEW ITEM, REFIT
REVERSING THE REMOVAL PROCEDURE.
SERVICE MANUAL
5 TO REPLACE THE CONTROL BOX
FOLLOW STEPS FOR REMOVING THE
INJECTOR
5:1 TAKE OFF THE 2 ALLEN SCREWS HOLDING
THE CONTROL BOX ASSY TO THE BASE (FIG.
17)
5:2 REMOVE THE SINGLE SCREW RETAINING
THE CONTROL BOX TO THE BASE
MOULDING
5:3 REPLACECONTROL BOXAND RE-ASSEMBLE
ALLCOMPONENTS
2 ALLEN
SCREWS
RETAINING
CONTROL
BOX ASSY TO
BASE
SINGLE SCREW
RETAINING
CONTROL BOX
TO BASE
MOULDING
FIG. 17
FIG. 18
FIG. 19

PAGE No 12
8 TO REPLACE THE PRESSURE SWITCH
FOLLOW STEPS FOR REMOVING THE
INJECTOR, BUT DO NOT REMOVE THE
INJECTOR.
8:1 TO REMOVE THE PRESSURE SWITCH,
REMOVE THE NEGATIVE AND POSITIVE
PRESSURE TUBES FROM THE SWITCH -
NOTING THAT THE POSITIVE TUBE GOES TO
THE REAR INLET ON THE SWITCH (FIG. 20).
8:2 UNSCREW THE SINGLE SCREW AND
REMOVE THE SWITCH SO THAT THE COVER
CAN BE REMOVED.
8:3 REMOVE THE COVER, AND REMOVE THE
POWER LEADS - NOTING THAT BROWN
GOES TO COMMON AND BLUE TO
‘NORMALLY OPEN’ (NO ON SWITCH).
3:4 REPLACE ALL COMPONENTS - REVERSING
THE STRIP DOWN PROCEDURE.
9 TO REPLACE THE SOLENOID
FOLLOW STEPS FOR REMOVING THE
INJECTOR, BUT DO NOT REMOVE THE
INJECTOR.
9:1 UNPLUG THE 3 WAY SOCKET FROM THE
SOLENOID (FIG. 21).
9:2 REMOVE THE FUEL INLET CONNECTOR UNIT
9:3 REMOVE THE SOLENOID RETAINING CIRCLIP
9:4 SLIDE THE SOLENOID OFF THE FUEL INLET
9:5 REPLACE THE DEFECTIVE UNIT AND REFIT
ALL COMPONENTS, REVERSING THE STRIP
DOWN PROCEDURE
SERVICE MANUAL
POSITIVE
TUBE GOES TO
REAR INLET
NEGATIVETUBE
GOES TO
FRONT INLET
BROWN
TO
COMMON REAR
INLET
FRONT
INLET
NEGATIVE
TUBE
BLUE
TO N.O.
FIG. 20
FIG. 21

PAGE No 13
FIG. 23
SERVICE MANUAL
10 TO REPLACE THE SOLENOID VALVE
FOLLOW STEPS FOR REMOVING THE
INJECTOR, BUT DO NOT REMOVE THE
INJECTOR.
10:1UNPLUG THE 3 WAY SOCKET FROM THE
SOLENOID (FIG. 22, 23)
10:2REMOVE THE FUEL INLET CONNECTOR UNIT
10:3REMOVE THE SOLENOID RETAINING CIRCLIP
10:4SLIDE THE SOLENOID OFF THE FUEL INLET
10:5UNFASTEN THE BURNER NOZZLE FUEL INLET
FROM THE SOLENOID VALVE USING A 10MM
AF OPEN ENDED SPANNER
10:6REMOVE THE SOLENOID VALVE USING A
12MM AF OPEN ENDED SPANNER
10:5REPLACE THE DEFECTIVE UNIT AND REFIT
ALL COMPONENTS, REVERSING THE STRIP
DOWN PROCEDURE
NOTE ON THE UNDERSIDE OF THE VALVE
THERE IS AN ARROW - THE VALVE MUST BE
FITTED WITH THIS POINTING TO THE
NOZZLE INJECTOR FUEL PIPE
FIG. 22
3 WAY
SOCKET
SOLENOID
CIRCLIP
VALVE