User manual ULTAMAGIC HOT AIR BALLONS MAINTENANCE MANUAL

[. . . ] MAINTENANCE MANUAL for ULTRAMAGIC HOT AIR BALLOONS H 31 42 56 65 77 V 25 56 65 77 90 105 S 90 105 130 160 T 150 180 210 F Special Shapes Serial number Approval Date _________ Rev. 11 _________ M 42 56 56C 65 65C 77 77C 90 105 120 130 145 160 N 180 210 250 300 355 425 Z 90 ULTRAMAGIC, S. A. Aerodrom Igualada-Odena s/n 08700 IGUALADA (SPAIN) tel +34 93 8042202 fax +34 93 8035604 e-mail admin@ultramagic. com web www. ultramagic. com Document name : MM04 Initial Issue date 24 Sept. 2003 The content of this manual has been approved under the privilege of the Design Organisation Approval nr. 11 ULTRAMAGIC, S. A page 0. 1 LIST OF APPROVED REVISIONS See list of effective pages. [. . . ] Set the position of the pilot light element assembly to ensure the correct gap setting between the tag and the igniter electrode as specified in section 4. 3. 11. 10 Having replaced the pilot light, the joint between the bulkhead coupling and the valve block must be pressure tested. If any bubbles are detected then the leak must be corrected before further burner use. If the above procedure fails to improve the pilot light flame, then it is likely that a fault exists with the pilot regulator valve. For maintenance procedures on the pilot regulator valve, refer to section 4. 3. 11. 8. 4. 3. 11. 12 Liquid fire Jet Assembly To remove and strip down the liquid fire jet assembly, refer to figure 11 and proceed as follows: · · · · · Locate the liquid fire adapter item 2. Using a suitable spanner, undo and remove the entire assembly by unscrewing the adapter from the valve block. Always fit new bonded washers, item 3 when replacing the assembly. HOT AIR BALLOON MAINTENANCE MANUAL MM04 Rev. 10 · ULTRAMAGIC, S. A 4. 33 Having re-assembled the liquid fire jet assembly to the valve block, the joints between the adapter and the valve block and the adapter and body must be pressure tested. If ant bubbles are detected, the problem must be resolved before further burner use. 4. 3. 11. 13 Slurper Tube Assembly To adjust the slurper tube to optimise performance, refer to figure 12 and proceed as follows: · · · · · Undo but do not remove the grub screw item 3. Adjust the slurper tube, item 1, position such that the bottom of the tube is approximately 1mm above the machined recess in the upper surface of the valve block. If required, the slurper tube assembly may be completely removed by unscrewing the cap head fixing screw. Re-assembly is the reverse process of removal. 4. 3. 11. 14 Hydraulic Main Valve Assembly The hydraulically operated main valve is an optional fit. To remove the hydraulic main valve assembly from the valve block, refer to figure 13 and proceed as follows: · · Undo and remove the cap-head fixings item 10 from all positions where the burner handle is attached. Withdraw the burner handle as an assembled item. HOT AIR BALLOON MAINTENANCE MANUAL MM04 Rev. 10 · ULTRAMAGIC, S. A 4. 34 Remove the valve assembly from the valve block as described for the standard main valve in section 4. 3. 11. 6 For further maintenance work, refer to figure 14 and proceed as follows: HOT AIR BALLOON MAINTENANCE MANUAL MM04 Rev. 10 ULTRAMAGIC, S. A 4. 35 · · · · · · · · · · · · · · · · · · There are no user serviceable parts in the remote hand lever and repair is by replacement. The seals inside the valve may be replaced as follows: Using an open ended spanner, undo and detach the hose female spin coupling from the adapter item 13. Using a pair of external circlip pliers, remove the circlip item 9 from the pivot pin item 7. When removing the handle, take care to ensure that the spring item 11 and spring cap item 10 do not spring out of the recess in the valve handle cam. Remove the valve seat sleeve item 4 and the valve seat assembly item 3. Check the rubber seal in the valve seat for signs of damage or shrinkage. A small circular witness mark on the seal surface is normal and indicates the position of contact between the seal and the valve block. If the seal is damaged or shows signs of shrinkage, it must be replaced. For safety, the seal is supplied as a complete assembly and no attempt should be made to replace the seal only. [. . . ] Check all welds for cracks with a magnifying glass. YES NO INSP. Frame Frame BURNER Burner 1. Check the complete burner for signs of wear or damage paying particular attention to the areas subjected to high temperatures. If found to be weak then inspect the pilot light fuel filter and jet for contamination and replace if necessary. Carry out a full functional check of the burner ensuring all valves open and close correctly. [. . . ]