A good maintenance program is essential to the lasting operation of your Johnston burner. Properly maintaining the burner will reduce unnecessary downtime, lower repair costs, and increase safety.
All electronic and mechanical systems require periodic maintenance. Automatic features do not relieve the operator from maintenance duties.
Any unusual noise, improper gauge measurement, or leak can be a sign of a developing problem, and should be taken care of immediately.
B. Component-Specific Maintenance
Most of the components and systems of your Johnston burner require little maintenance other than regular inspection. Cleanliness is essential to the inspection of the burner. Keep the exterior free of dust. Keep the controls clean. Clean dust and dirt from the motor starters and relay contacts.
See individual component manuals for more information on specific component maintenance issues.
C. Maintenance Schedule
Johnston Boiler Company recommends the following maintenance schedule for the upkeep of your Johnston burner. Any omission from this schedule could cause the Warranty to be voided. Only qualified and experienced boiler, burner, and control personnel should attempt any maintenance and/or repair on any boiler/burner. Be sure you have read and understood this entire manual before attempting maintenance or repair.
This maintenance schedule assumes a Johnston burner. Refer to your boiler manual for trim and boiler maintenance.
The following maintenance tasks should be performed daily by the operator:
1. Check boiler manual for all items pertaining.
2. Check over the boiler and burner for proper operating pressures and temperatures.
3. Check the startup and operation of the burner pilot and main flames. Check the appearance of
the flames for proper and stable combustion. Standard electrode setting is 1/8” to 3/16” gap.
4. For oil-fired burners, check the operation of the fuel oil pump, heater (for heavy oil) and air
compressor. Check the oil level in the compressor. Check the condition of the fuel oil strainer for
5. Check to make sure that an adequate air supply into the boiler room is being maintained. Check
to make sure that the inlet screen on the blower assembly is clean and free from obstruction.
6. Check for fuel and air leaks. Any leaks in the piping, fittings, controls, should be attended to
7. Replace failed indicating lights and ensure that all alarms are operational.
8. Maintain a clean, orderly, and safe boiler room.
The following maintenance tasks should be performed weekly by the operator:
1. Check the burner linkage joints, arms, and rods for tightness. Check the linkage firing rate motor
(MOD motor), shafts, bearings, and flow control fuel valves for proper and smooth operation.
2. If a heavy oil burner, clean the oil gun assembly. In cleaning the oil nozzle, disassemble and
clean with solvent and compressed air.
3. Grease the burner blower shaft bearings sparingly (only while in operation). See the
manufacturer‟s recommendations for lubricating the blower motor.
4. If installed, check the boiler outlet flue gas damper for proper and smooth operation.
5. Check the peepsite and sightports for cracks in the lens.
The following maintenance tasks should be performed monthly by the operator:
1. Check the burner pilot assembly for cleanliness and proper condition. Check the electrode for
cracks in the porcelain and proper adjustment. Check the condition of the lead wire, and its
connectors. Standard electrode setting is a 1/8” to 3/16” gap.
2. Check the flame scanner for cleanliness. Check the condition of its connecting cable.
3. If a light oil fired burner, check the oil gun assembly for cleanliness and condition. Clean as may
be required. In cleaning the oil nozzle, disassemble and clean with solvent and compressed air.
4. Check the blower assembly condition, cleanliness and proper operation, including the motor,
blower wheel, air damper, and linkages.
5. If a heavy oil fired burner, check the operation of the steam trap for the oil preheater.
6. If a gas fired burner, check the main gas valves for proper, smooth operation.
7. If a combination fuel burner, check the fuel selector shifter mechanism for tightness and proper
8. Check operation of the surface or continuous blowoff valve.
9. Change oil in air compressor after 500 hours of operation.
The following maintenance tasks should be performed annually by the operator:
1. Check the condition of the burner internals, including the swirlers, main gas ring, oil gun assembly
and burner refractory.
2. Check gauges and thermometers for proper calibration.
3. Open, clean and inspect the burner fireside. Inspect the condition of the refractory, Hairline
cracking in the refractory is normal. Loose or missing pieces in the refractory must be patched,
repaired, or replaced.
4. Check the condition of the fireside gasketing. Check for hardness and/or cracking. Replace
fireside gasketing as needed, but not less than every three years.
Click HERE for Boiler Room Log.