OPERATOR’S AND PARTS MANUAL
MAY 2009
MAXI-HEAT® SERIES
MODEL MH-1000
Beginning with Serial Number 0001MXH09
ALLMAND BROS. INC
P.O. BOX 888
HOLDREGE, NE 68949
PHONE: 308/995-4495, 1-800/562-1373
FAX: 308/995-5887
PARTS FAX: 308/995-4883
MAXI-HEAT® SERIES
REV G-1 IDF 500
For Parts and Updates visit Allmand on the Web at www.allmand.com
TABLE OF CONTENTS
OPERATORS MANUAL |
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Inspection Check List..................................................................... |
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3 |
Introduction.................................................................................... |
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4 |
Safety Decals................................................................................. |
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5 |
Set-up Procedure........................................................................... |
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8 |
Specifications................................................................................. |
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9 |
Serial Number Location.................................................................. |
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9 |
Fuel and Lubricating Oil............................................................... |
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10 |
Starting Procedure........................................................................ |
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11 |
Maintenance and Towing Instructions.......................................... |
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12 |
Troubleshooting Heaters.............................................................. |
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13 |
Electrical Schematics................................................................... |
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17 |
Ductwork Installation Options....................................................... |
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22 |
PARTS MANUAL |
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Trailer Assembly Parts and Accessories................................ |
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A 1A |
Heater Assembly Parts and Accessories............................... |
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B 1A |
Engine/Generator Assembly Parts and Accessories............. |
C 1A |
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Optional Parts and Accessories.............................................. |
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D-1A |
Decals..................................................................................... |
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E 1A |
Warranty............................................................... |
Inside Back Cover |
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Note: Call out item numbers are continuous through each section of the parts manual.
RECORDS
Serial Number:
Model Number:
Engine Type:
Engine Serial Number:
Accessories:
2
INSPECTION CHECK LIST
PREPARING THE MAXI HEAT FOR DELIVERY OR RENTAL
The Allmand Maxi Heat® 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. Always provide the manual with the equipment for proper and safe operation.
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 good condition and proper inflation.
Check lug nuts and torque to 80-90 ft. lbs. Lug nuts should be retorqued after first 100 mi of towing.
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 filter, air cleaner and engine oil (see operator’s manual).
Check the oil, fuel and coolant levels.
Start engine and turn heaters on to ensure proper operation.
Check to make sure the operator’s manual is with the equipment.
NOTE: See operator’s manual for scheduled maintenance intervals.
SAFETY WARNING!
NEVER ALLOW ANYONE TO OPERATE THE EOUIPMENT WITHOUT
PROPER TRAINING.
ALWAYS READ THE INSTRUCTIONS FIRST.
3
INTRODUCTION
This manual provides the information necessary for the safe operation and maintenance of the Allmand Maxi-Heat®.
Specific operating details and specifications are contained in this publication to familiarize the operator and maintenance person with the correct and safe procedures necessary to maintain and operate this equipment.
Take time to read this book thoroughly. If you are uncertain about any of the information contained in this manual, contact your dealer for clarification before operation of the machine.
SAFETY SYMBOLS
The purpose of the SAFETY INFORMATION SYMBOL shown below is to attract your special attention to safety-related information contained in the text.
SAFETY WARNING!
FAILURE TO UNDERSTAND AND COMPLY WITH SAFETY RELATED INFORMATION AND INSTRUCTIONS MAY RESULT IN INJURY TO THE OPERATOR OR OTHERS. IF YOU DO NOT UNDERSTAND ANY PART OF THIS INFORMATION CONTACT YOUR DEALER FOR CLARIFICATION PRIOR TO OPERATING EQUIPMENT.
NOTE: The word NOTE is used to bring your attention to supplementary information in relation to various aspects of proper operation and
maintenance.
NOTE: Keep this manual accessible during operation to provide convenient reference.
NOTE: Any reference in this manual to LEFT or RIGHT shall be determined by looking at the trailer from the REAR.
4
SAFETY DECALS
SAFETY WARNING!
ALWAYS REPLACE ANY SAFETY AND INSTRUCTION DECALS THAT BECOME DAMAGED, PAINTED, OR OTHERWISE ILLEGIBLE.
Refer to these reperesentations of the safety warning decals used on the Maxi-Heat to insure correct
ordering if replacing becomes neces-
PART NO. 090023
Inside Rear Door
PART NO. 090120
Left Side of Trailer
PART NO. 090147
Inside Heater Outlet Door
PART NO. 090042
Inside Rear Door
PART NO. 090163
Breaker Box Lid in
Engine Compartment
PART NO. 090179
Inside Rear Door
PART NO. 090143
Inside Rear Door
PART NO. 090108
Left Side of Trailer
PART NO. 090122
Right Side of Trailer
PART NO. 090133
Left Side of Trailer
5
SAFETY DECALS
HEATER OPERATING INSTRUCTIONS
PART NO. 09007 Inside Rear Door
Inside Rear Door
PART NO. 090304 |
FAN SHUTDOWN INSTRUCTIONS |
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Inside Rear Door |
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Inside Rear Door |
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6
SAFETY DECALS
PART NO. 100910
CAUTION
1). NEUTRAL BONDED TO FRAME
2). MACHINE TO BE GROUNDED IN ACCORDANCE WITH REQUIREMENTS AS OUTLINED BY LOCAL INSPECTIONS AUTHORITIES
3). TURN OFF ALL POWER BEFORE SERVICING
4). THE REQUIREMENTS OF LOCAL AUTHORITIES HAVING JURISDICTION SHALL BE FOLLOWED
5). DO NOT START THE HEATER WHEN EXCESS OIL HAS ACCUMULATED IN THE CHAMBER 6). DO NOT FILL THE TANK WHILE THE UNIT IS OPERATING
7). DO NOT TAMPER WITH THE UNIT. ONLY COMPETENT SERVICEMEN SHOULD MAKE ADJUSTMENTS 8). DO NOT OPERATE THE UNIT IN CLOSE PROXIMITY TO COMBUSTIBLE SURFACES OR MATERIALS
101062
PART NO. 101062
GENERAL CAUTION STATEMENT
GROUND ROD USE INSTRUCTIONS
1). Remove the ground rod stowed inside trailer (on left side, near engine)
2). Unroll the electrical wire lead from the ground rod
3). Drive the ground rod a minimum of 2-1/2 FT into the earth for adequate electrical ground. Consult local authorities for more information.
4). Attach the ground rod lead wire to the ground lug
5). AFTER SHUTDOWN OF MACHINE: Remove the lead connecting the ground rod to the unit; remove the
ground rod from the earth; and return ground rod to storage location inside trailer |
101063 |
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PART NO. 101063 |
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GROUND ROD USE INSTRUCTIONS |
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7
MAXI-HEAT® SETUP PROCEDURE
The Frost Fighter heater units need to be set up for each operation and tuned to operate efficiently depending on the altitude of intended use. As you go up in elevation, the air gets thinner. As the air gets thinner the ability to burn or consume a certain amount of fuel is diminished. When you move the machine to a different elevation you may need to change the nozzle size and air settings to get a clean
efficient burn. The nozzle size is determined by the number of gallons per hour number (GPH). A number is stamped on the nozzle indicating the amount of fuel that the nozzle will deliver to the burning chamber. For higher elevations, selecting a nozzle that delivers less fuel allows you to make the air mixture adjustments needed to burn all of the fuel with less air (thinner air).
Test Equipment:
Bacharach Oil Burner Smoke Tester – is used to determine the amount of soot in the exhaust gasses. This can indicate the level of combustion being achieved. It is recommended that the Smoke Tester be used for tuning the Maxi Heat Frost Fighters.
Instructions for setting up the Maxi Heat at elevations above sea level.
1.Install fuel pressure gages (if not equipped).
2.Set Fuel Pressure to 140 PSI
3.Head Setting at #6.
4.Shutter Setting – Full open. #10 Setting.
·Fine adjustment – very little change in air mixture results when changing the settings from 1 to 10.
5. Band Setting - ½ open. — #5 Setting
·Starting at 50% open allows adjustment in both directions during tuning.
6.Install nozzle size that gives a medium to good burn (2 or 3) on True-Spot Smoke Tester
·While the fuel pressure is maintained at 140 PSI, Head Setting at #6, and Shutter and Band Settings are at the #10 and #5 settings, test nozzles until you have a nozzle that gives satisfactory initial smoke tester readings.
·Example:
1.Initial startup with settings as noted above ( Fuel 140 PSI, Shutter #10, Band #5) gives a smoke reading between 6 & 9 (heavy smoke on test strip with visible smoke coming from the stack and possibly a rumbling sound coming from the burner.
2.Smoke indicates too much fuel or not enough air. (fuel not being totally burned)
Action:
1.Turn off switch and let the Frost Fighter cool down.
2.Shut off the power to the Frost Fighter.
3.Remove Fuel Rail, and determine the nozzle rating in GPH (gallons per hour) e.g. 3.
4.Select a nozzle that has an output lower than 3. (Read the following suggestions for selecting a nozzle size and depending on the initial startup and smoke test readings you can make an informed decision on which nozzle to select.
·For heavy smoke and a rumbling sound you may select a 2.5 GPH nozzle for the next test.
·For heavy smoke and no rumbling, you may want to select a 2.75 GPH nozzle for the next test.
5.Install nozzle,
8
MAXI-HEAT® SETUP PROCEDURE
6.Check igniter tips for correct location for the unit you are setting up. Adjust if necessary. (see owners manual)
For the IDF 500:
·5/32 apart
·¼” above center of nozzle
·1/8” in front of nozzle
7.Re-install the fuel rail, hook up fuel lines etc.
8.Restart the heater and check the flue gas for smoke using the True-Spot Smoke Tester.
9.If you get a smoke test reading in the 2 to 3 range you will be ready to fine tune the burner to achieve a #1 or possibly a 0 on the smoke scale. If you still have heavy smoke, you may have to go down another nozzle size to be able to get the burner to burn efficiently.
Fine Tuning the Frost Fighter Burners
1.Use the True-Spot Smoke Tester to determine where you are on the Smoke Scale.
2.To reduce the amount of smoke, open the band 1 or 2 numbers and recheck with the True-Spot Smoke Tester.
3.Make further adjustments if necessary to achieve the lowest number you can on the Smoke Scale.
4.Tighten the air band and shutter-securing screws to prevent them from moving after you have made the adjustments.
SPECIFICATIONS AND SERIAL NUMBERING LOCATION
DIMENSIONS
Height: |
6’ |
Length: |
16’ |
Width: |
6’ 8” |
WEIGHT
Empty: |
3,500 lbs. |
With Fuel: |
4,651 lbs. |
ENGINE/GENERATOR |
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ISUZU 3CE1 Diesel Engine |
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Starting: |
12V Electric 8D Battery |
Oil sump capacity: |
6.7 qts (6.3 L) |
Low Oil Pressure Shutdown: Solenoid actuated fuel
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rack instant shutdown |
Generator: |
8kW , 60 Hz, 1-ph, 1800 rpm |
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CAT C1.5 Diesel Engine |
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Starting: |
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12V Electric 8D Battery |
Oil sump capacity: |
5.9 qts (5.6 L) |
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Low Oil Pressure Shutdown: Solenoid actuated fuel
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rack instant shutdown |
Generator: |
8kW , 60 Hz, 1-ph, 1800 rpm |
FUEL SYSTEM
Fuel Requirements: |
No.1 fuel oil |
Fuel Capacity: |
191.1 Gallons |
Fuel Consumption: |
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Engine: ISUZU 3CD1 |
0.5 gal/hour (1.9L/ |
hr) |
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Engine: CAT C1.5 |
0.5 gal/hour (1.9L/hr) |
HEATERS
Two (2) I.C.E. Frost Fighter IDF 500
325,000 BTU Output with 2.5 gph, 60° solid nozzle
Each standard heater includes one (1) 16 in. heated air outlet, which connects easily to the ducting. Limit to 110feet of 16” ducting.
Heated Air Output: 2,850 CFM per heater w/o duct.
Temperature Rise:185° with duct creating 0.5 in. static pressure
Operating Time: More than 24 hours without refuel-
SERIAL NUMBER LOCATIONS
TRAILER: Plate attached to right rear corner of frame
ISUZU ENGINE: Plate attached to top of valve cover
CAT ENGINE: Plate attached to injector pump on right side of engine
9
FUEL AND LUBRICATING OIL
The temperatures mentioned in the table are
the ambient temperatures at the time the engine is started. However, if the running ambient temperatures are much higher than the starting temperatures, a compromise must be struck and a higher viscosity oil used (provided starting is satisfactory).
Multigrade oils overcome the problem provided they have a suitable specification.
NOTE: In testing this engine at the factory, the manufacturer uses on oil for moderate and low temperatures. This oil is specially formulated to assist in the break in period, and the manufacturer would like this oil to be left in the engine for the first 50 hours. Additional information on fuel and lubrication specifications can be found in the Engine Instruction
Manual.
FUEL AND LUBRICATING OIL REQUIREMENTS
Periodic Maintenance Schedule
Isuzu 3CD1 |
CAT C1.5 |
10
STARTING PROCEDURES
BEFORE STARTING:
1.Fill the engine with the specified grade and quantity of lubricating oil to correct level (check dipstick).
2.Ensure there is an adequate supply of fuel.
3.Ensure that the air cleaner is firmly attached and air joints are properly sealed. Air cleaner element should be checked and replaced if necessary.
HEATER STARTING:
NOTE: Circuit breakers for heaters must be switched to the ON position.
NOTE. Allow engine to come to full RPM and warm up before starting heaters.
1.With engine operating, turn toggle switch at heater to manual position.
STARTING ENGINE
1.Heater switches must be in OFF position. 2.Open door for heater outlets.
NOTE: Engine will not start with heater outlet door closed.
3.Turn the key switch to the PREHEAT position,hold until the glow indicator light goes out, then release switch.
4.Turn the key switch to the START position and the engine should start. Release the key immediately when the engine starts. If engine fails to start it may be necessary to cycle the glow plugs again.
NOTE: If engine fails to start, see engine opera-
tors
handbook for cold start procedures.
NOTE: The low engine oil pressure shutdown solenoid is activated by an oil pressure switch, therefore it will take several seconds of engine cranking to build oil pressure in the switch before fuel will be allowed to the engine.
OPERATING INSTRUCTIONS
1.Do not start heater when excess oil has accumulated in chamber.
2.Do not fill fuel tank while unit is operating.
3.Do not shut off by disconnecting supply cord. 4.Do not use gasoline, crankcase oil or heavier
IF HEATER FAILS TO START:
1.Press and hold manual reset button on burner relay for 30 seconds.
2.Check fuel level.
3.Check fuel filter and suction tubing.
4.Check nozzle assembly.
SAFETY WARNING!
BEFORE TURNING THE ENGINE OFF, THE HEATERS MUST BE SWITCHED TO THE POSITION WHICH ALLOWS THE FANS TO COMPLETE A COOL DOWN CYCLE FOR THE HEAT EXCHANGER
TO STOP HEATER:
Flip switch to “OFF” position
SAFETY WARNING!
BURNERS WILL STOP BUT THE FAN WILL AUTOMATICALLY CONTINUE TO CYCLE UNTIL THE UNIT COOLS DOWN
ENGINE SHUTDOWN:
1.Shut heater off. Allow time for the fans to turn off.
2.Turn ignition switch to “OFF” position.
11
MAINTENANCE AND TOWING INSTRUCTIONS
NOTE: DO NOT TAMPER WITH UNIT. HAVE A COMPETENT SERVICEMAN MAKE ANY ADJUSTMENTS.
NOTE: Before moving guards out of position insure power cord is disconnected.
SAFETY WARNING!
FAN COULD CYCLE ON AUTOMATICALLY
High Limit Switch:
The limit switch should be checked every heating season to insure the burner will shut down if temper-
ature exceeds 200° F
*This can be done by restricting the air flow through the unit. After tests are complete, re-
move
restrictors as ducts must be open for proper operation.
Fan Switch:
The adjustable fan switch will turn on the fan when the heat exchanger temperature is at 900F and off at 600F. If the fan fails to stop when the heat exchanger has cooled, replace switch.
Fuel Filter:
Replace element at least every six months of normal usage, or more frequently in dirty conditions.
Flame Detector:
The flame detector is located in the burner housing below the transformer. Periodically clean cell detector face with
a soft nonabrasive cloth.
Burner:
The electrode spacing must be checked and adjusted, if necessary, after every nozzle change. Nozzles should be replaced annually or sooner if burner cannot be set up to operate properly. Nozzle size is dependent on altitude of operation. Nozzle size and type are marked on the rating plate.
Motors:
No lubrication is necessary since the bearings are the sealed type.
Fuel System:
Do not store unit containing fuel oil for long periods.
NOTE: Service intervals have been established for operation under normal conditions. Where equipment is operated under severe conditions(very dusty, extreme cold, etc.) affected items should be serviced more frequently. For detailed information see the Engine Instruction Manual for Heater Unit Installation-Operating
Maintenance instructions.
CLEANING PROCEDURE
The unit should be cleaned periodically as follows:
1.Remove front cap.
2.Remove cover panel (jacket to front).
3.Remove fan thermostat cover on outer jacket
(on the nearest burner). Loosen the thermostat and remove from the jacket. Remove high limit thermostat.
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).
TOWING INSTRUCTIONS
Before towing the Maxi Heat, the trailer should be inspected visually to assure that the following operations have been completed:
1.Hitch is securely attached to towing vehicle
(safety chain secured).
2.Front jack retracted.
3.Ducting removed from heaters and stored.
4.Doors are closed and secure.
5.Check for adequate tire pressure.
6.Taillights are connected and operating.
7.Remove ground rod from earth and secure in trailer.
12
TROUBLESHOOTING
13
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