Essential Diesel Heater Maintenance Tips for Winter

Diesel heaters are essential in keeping workshops and warehouses, especially during the colder months. However, poor diesel quality, freezing temperatures, and lack of proper maintenance can significantly impact their performance. One of the most common problems that diesel heaters face in winter is wax crystallisation, which can block fuel lines and filters, reducing efficiency or total heater failure.

This guide provides a detailed breakdown of common diesel heater issues, maintenance procedures, troubleshooting tips, and best practices to ensure long-term performance. To illustrate these points, the Remington RPH75R Diesel Heater is an example throughout this blog post, highlighting its features, maintenance requirements, and how to keep it running efficiently in challenging conditions.

RPH75R Diesel Heater Specifications

The RPH75R Diesel Heater is designed to deliver efficient and powerful heating for industrial applications. Key specifications include:

• Heating Capacity: 70,000 BTU (21 kW), capable of warming areas up to 162 square meters.
• Fuel Type: Multi-fuel capability, operating efficiently on diesel or kerosene.
• Fuel Tank Capacity: 15 litres, providing up to 6 hours of continuous heating.
• Portability: Weigh approximately 13 kg, making it easy to transport.
• Noise Level: 71 dBA at 1 meter, ensuring a relatively quiet operation compared to other industrial heaters.

The RPH75R Diesel Heater is designed for quiet, efficient, and reliable operation, making it an ideal choice for workshops, construction sites, and industrial warehouses. Unlike traditional forced air heaters, it features Silent Drive technology, which reduces noise by approximately 50%, ensuring a quieter work environment. The dedicated combustion air system provides a tightly controlled air-to-fuel ratio, resulting in cleaner combustion and improved fuel efficiency. Users can precisely control the temperature with a built-in thermostat, optimising fuel consumption while maintaining a comfortable workspace. The high-performance pump is not air pressure sensitive, guaranteeing consistent performance even in extreme cold weather. The heater also includes a cool-down cycle, which helps extend the lifespan of internal components, reducing the need for frequent maintenance.

Visit Remington Power for more information on the RPH75R and to explore its full range of industrial heaters.

Understanding Wax Crystallisation in Diesel Fuel

Wax crystallisation is a common problem for diesel heaters operating throughout the winter months. All diesel fuel contains paraffin wax, which enhances its combustion properties. Under normal temperatures, this wax remains in liquid form. However, when temperatures drop too low, the wax solidifies into crystals, causing fuel filters and line blockages. This can result in:

• Fuel starvation, making it difficult for the heater to start.
• Fluctuating or reduced heat output due to inconsistent fuel flow.
• Complete heater shutdown in severe cases.

How to Identify Waxing Problems

• Cloudy or milky fuel inside the fuel tank.
• White/yellow deposits in the fuel lines or filters.
• The heater is hard to start or won’t start at all due to fuel blockages.

How to Prevent Wax Crystallisation

• Use Winter-Grade Diesel: These fuels have lower wax content, making them less likely to crystallise in colder temperatures.
• Add Fuel Additives: Anti-gel additives help prevent wax formation and keep fuel flowing smoothly.
• Store the Heater Indoors: After use, cover the heater to prevent the fuel from cooling down too much.

Blending Diesel for Cold Weather Performance

Mixing diesel with kerosene can help lower the cloud point, reducing the risk of fuel waxing. The following table provides recommended blend ratios for different heater models:

Using the correct blend ensures stable performance in low temperatures and reduces the likelihood of fuel system blockages. Additionally, ensuring that only clean and adequately stored fuel is used prevents long-term damage to the heater’s internal components.

Recommended Maintenance Schedule

To ensure the longevity and efficiency of a diesel heater, routine inspections and servicing should be carried out. Below is a recommended maintenance schedule, followed by an example of the RPH75R maintenance schedule:

Preventative Maintenance Schedule for the RPH75R Heater

Proper maintenance is essential to keep your RPH75R Diesel Heater running efficiently throughout the winter. Here’s what you need to do:

1. Fuel System Maintenance

• Fuel Filters: Inspect twice a month for blockages. Replace at least once a year.
• Fuel Nozzle: Clean monthly with kerosene or diesel to remove residue. Replace annually.
• Fuel Tank: Drain and flush after long periods of non-use to prevent fuel degradation.

2. Combustion System Maintenance

• Spark Plug: Clean and re-gap every 600 hours of operation. Ensure a 3.5mm spark gap.
• Burner Body & Nozzle: Keep free of carbon buildup to ensure proper combustion.

3. Air System Maintenance

• Check Air Intake & Exhaust: Ensure proper ventilation to prevent overheating. 
• Clean Fan Blades: Dust and debris can reduce efficiency—inspect monthly.

4. Photocell Sensor Cleaning

The photocell sensor detects flame presence. A dirty sensor can cause the heater to shut down unnecessarily. Clean it with a soft cloth once per heating season.

Storage and Long-Term Care

Proper storage practices are necessary to maintain efficiency and prevent fuel-related issues. Before storing the heater for extended periods, the following steps should be taken:

• Store the heater indoors and cover it to protect against dust and moisture.
• Drain any unused diesel to prevent contamination.
• Ensure all components are dry before storage to avoid corrosion.

These precautions help prevent operational issues when the heater is next used, reducing downtime and maintenance costs.

Safety Considerations for Diesel Heater Use

Diesel heaters, including the Remington RPH75R, require adequate ventilation for safe operation. Since they consume oxygen from the surrounding air, proper airflow is necessary to prevent carbon monoxide build-up. Users should ensure their workspace has sufficient ventilation before operating the heater.

Safety Guidelines: 

• Never use diesel heaters in enclosed spaces without proper ventilation.
• Keep combustible materials such as wood, paper, or solvents at a safe distance.
• Always check for fuel leaks before operation.
• Use only the recommended fuel type and avoid mixing with unapproved substances.
• Please do not modify the heater or use unauthorised parts, which may compromise safety.

For comprehensive safety guidelines, refer to the Remington RPH75R User Manual, which includes operating instructions, ventilation requirements, and important warnings.

Troubleshooting Common Issues

Even with proper maintenance, users may occasionally encounter issues. Below are some common problems and their potential solutions:

1. Heater Won’t Start

• Check the Fuel: If it looks cloudy, the wax may have crystallised—warm it up or add anti-gel.
• Inspect the Fuel Lines: Blockages can prevent fuel from reaching the burner.
• Verify Electrical Connections: Loose power connections may stop the heater from starting.

2. Weak or No Flame 

• Check the Fuel Nozzle: A clogged nozzle can prevent proper combustion. Clean or replace if necessary.
• Inspect the Air Pump Pressure: Low air pressure can cause weak flames—adjust if needed.
• Clean the Photocell Sensor: If the sensor is dirty, the heater may shut off prematurely.

3. Unusual Noises 

• Grinding Sound on Startup: This may indicate air in the fuel lines—ensure the fuel tank is adequately filled.
• Rattling or Vibrating: Loose internal parts could be the cause—tighten any visible fasteners.

Regular maintenance ensures diesel heaters operate at peak efficiency while reducing downtime due to malfunctions. Preventative care includes monitoring fuel quality, cleaning key components, and using the correct fuel blend for cold conditions. By following the recommended maintenance schedule and adhering to best practices, users can extend the lifespan of their diesel heaters while ensuring consistent performance.

Looking for reliable industrial heating solutions? Visit Proline Industrial today to explore our range of high-performance heaters and get expert advice on keeping your workshop warm this winter!