Aqua Hot leaking Boiler fluid

If NOT winterized properly, the fluid would leak out the overflow reservoir when water pump or city water was connected. If you have fluid leaking out that elbow, have you smelled that fluid? A non firing diesel burner will leak out excess diesel at that elbow. The ONLY way to verify a bad weld or inner tank crack is to pull the Aqua Hot and remove the various outer shells and insulation. If this is the case the ONLY fix is to buy a new unit or send back to Aqua Hot for a rebuild. Doug

It WAS winterized properly. This is my 11th RV and not my first aqua hot. I never hook up to city water. I use pump only. It fires up perfectly and works on electric also. Fluid leaking is definitely boiler fluid. I replaced 3.5 gallons of it in a week. Hard to believe this unit is bad with so little use.

zb, call me between 8 and 8 central and I will help you sort this out. I am a Authorized Aqua Hot Service Center, so I have 14 years experience to call upon to assist you. But what you are describing does not sound like a minor repair. But a few questions will solve that.

You do not need a new heater and that expense. So call me and lets see what we can deterine.

Rudy Legett 7 one 3 8 one 8 3234

I have an AquaHot so I am very interested in what you guys come up with.

BTW, I have heard good things about Rudy. I would definitely accept his offer to help.

Call Rudy he knows his stuff big time, he did some work on our monaco in 2020. Good to see your still working Rudy! Phil

Great talking to Rudy this am. Super helpful! I will do some checking and call you back.

I took the burner out. Easy, only 2 bolts and fuel lines. Got a better look at drain pipe. Very wet around there. Took out combustion chamber and found some fluid in bottom. Will be putting 15lbs of air into it to see if I can locate leak. I'll update as I go. I'll keep going until I find something. I took pics but can't seem to post them.

Update. Rudy is SUPER nice and very helpful. After putting air to the boiler I could see it was seeping into the burn chamber VERY slowly. Ruday and I discussed what it would take to try and weld this. Tons of work!! I elected to put it back together. It only leaks when I run the diesel boiler, it does not leak on electric. I have many ways to heat the coach. heat pumps and heated floors. I put it back together and added some BARS stop leak to the system. I then topped it off with boiler fluid and fired it up for 4 hours. It slowly sucked in another gallon of fluid. I did drain it some before I fired it up so there would be room for the stop leak. I never saw a drop in the 4 hours it ran. It ran hard to because I had all the zones on and it's cold here.
When it cooled down it brought the over flow tank to right in the middle between the hot line and the cold line. 2 days later it still has not leaked a drop. At this point, I feel pretty good about it. Only time and multiple uses will tell the complete story. Not sure when the coach will go out again but we will see.
Thanks again Rudy for all the GREAT advice and help. I enjoy working on most things and I learned some stuff about my unit. All good for now.

Sounds like you have a ruptured boiler, that's not good. I have read on another forum of using a similar sealer called Iron Tite with excellent results.
If your sealer fails give it a try.https://www.napaonline.com/en/p/NCB468913016

There is another Aqua-hot man called John Carillo https://www.heatmyrv.com/

I read the other day of an owner that John rebuilt his boiler and the owner reinstalled it saving thousands.

Thanks for another idea besides stop leak. I sent 2 emails to heatmyRV a week before I posted on here. He never replied.