Wacker Neuson DPP8.8 User manual

0174899en 003 0110

0174899EN

Operator’s Manual

Pump Pack

DPP 1000

Copyright

notice

All rights, including copying and distribution rights, are reserved.

This publication may be photocopied by the original purchaser of the machine. Any

other type of reproduction is prohibited without express written permission from

Wacker Neuson Corporation.

Any type of reproduction or distribution not authorized by Wacker Neuson Corporation

represents an infringement of valid copyrights. Violators will be prosecuted.

Trademarks

All trademarks referenced in this manual are the property of their respective owners.

Manufacturer

Wacker Neuson Corporation

N92W15000 Anthony Avenue

Menomonee Falls, WI 53051 U.S.A.

Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957

www.wackerneuson.com

Translated

instructions

This Operator’s Manual presents a translation of the original instructions. The original

language of this Operator’s Manual is American English.

Pump Packs Table of Contents

3

1. Foreword 5

2. Safety Information 6

2.1 Operating Safety .................................................................................. 7

2.2 Maintenance Safety .............................................................................. 8

2.3 Label Locations .................................................................................... 9

2.4 Safety and Operating Labels .............................................................. 10

3. Operation 12

3.1 System Description ............................................................................ 12

3.2 System Component Locations ........................................................... 13

3.3 Control Panel ...................................................................................... 14

3.4 Positioning the Machine ..................................................................... 14

3.5 Preliminary Checks ............................................................................ 14

3.6 Connecting the Pump Pack to Your Ground Heater™ Machine ........ 15

3.7 Connecting Power to the Machine ..................................................... 15

3.8 Starting the Machine .......................................................................... 16

3.9 Shutting Down the Machine ............................................................... 16

4. Maintenance 18

4.1 Periodic Maintenance Schedule ......................................................... 18

4.2 Lifting, Transporting, and Storing the Machine ................................... 19

4.3 Cleaning the Quick-Connect Couplings ............................................. 20

4.4 Cleaning the HTF Strainer Basket ...................................................... 21

5. Technical Data 22

5.1 Pump Packs ....................................................................................... 22

Table of Contents Pump Packs

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Foreword

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1. Foreword

This manual provides information and procedures to safely operate

and maintain this Wacker model. For your own safety and protection

from injury, carefully read, understand and observe the safety

instructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose this

manual or need an additional copy, please contact Wacker

Corporation. This machine is built with user safety in mind; however,

it can present hazards if improperly operated and serviced. Follow

operating instructions carefully! If you have questions about operating

or servicing this equipment, please contact Wacker Corporation.

The information contained in this manual was based on machines in

production at the time of publication. Wacker Corporation reserves the

right to change any portion of this information without notice.

All rights, especially copying and distribution rights, are reserved.

No part of this publication may be reproduced in any form or by any

means, electronic or mechanical, including photocopying, without

express written permission from Wacker Corporation.

Any type of reproduction or distribution not authorized by Wacker

Corporation represents an infringement of valid copyrights and will be

prosecuted. We expressly reserve the right to make technical

modifications, even without due notice, which aim at improving our

machines or their safety standards.

Foreword

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Pump Packs Safety Information

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2. Safety Information

This manual contains DANGER, WARNING, CAUTION, NOTICE and

NOTE callouts which must be followed to reduce the possibility of

personal injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this

symbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, will

result in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, could

result in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could

result in minor or moderate injury.

NOTICE: Used without the safety alert symbol, NOTICE indicates a

hazardous situation which, if not avoided, could result in property

damage.

Note: Contains additional information important to a procedure.

DANGER

WARNING

CAUTION

Safety Information Pump Packs

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2.1 Operating Safety

Familiarity and proper training are required for the safe operation of

this machine. Machines operated improperly or by untrained personnel

can be dangerous. Read the operating instructions contained in both

this manual and the OEM manuals included with this machine.

Familiarize yourself with the location and proper use of all controls.

Inexperienced operators should receive instruction from someone

familiar with the machine before being allowed to operate it.

NEVER use the Pump Pack machines to transfer any substance other

than Ground Heaters, Inc. Heat Transfer Fluid (HTF). Doing so could

result in personal injury, death, explosion, or damage to the machine.

2.1.1 NEVER use this machine with anything other than the intended

complementary Ground Heater™ machine.

2.1.2 NEVER connect the machine to an external power source. The

machine MUST be connected to the accessory power receptacle on

the complementary Ground Heater™ machine. If an additional Pump

Pack is desired, an Auxiliary Pump Panel must be installed to supply

power to the additional machine.

2.1.3 NEVER start a machine in need of repair.

2.1.4 NEVER transport people in or on the machine.

2.1.5 NEVER run the machine in areas that contain flammable objects,

fuels, or products that produce flammable vapors.

2.1.6 Keep unauthorized personnel, children, and pets away from the

machine.

2.1.7 ALWAYS be sure the machine is on a firm, level surface and will not

tip, roll, slide, or fall while operating.

2.1.8 ALWAYS operate machine with all safety devices and guards in place

and in working order. DO NOT modify or defeat safety devices. DO

NOT operate machine if any safety devices or guards are missing or

inoperative.

2.1.9 ALWAYS wear gloves when handling hoses and hot components.

WARNING

Pump Packs Safety Information

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2.2 Maintenance Safety

HIGH VOLTAGE! This unit uses high voltage circuits capable of

causing serious injury or death. Only a qualified electrician should

troubleshoot or repair electrical problems occurring with this

equipment.

2.2.1 DO NOT use gasoline or other types of fuels or flammable solvents to

clean parts, especially in enclosed areas. Fumes from fuels and

solvents can become explosive.

2.2.2 ALWAYS replace the safety devices and guards after repairs and

maintenance.

2.2.3 ALWAYS keep the machine clean and labels legible. Replace all

missing and hard-to-read labels. Labels provide important operating

instructions and warn of dangers and hazards.

2.2.4 ALWAYS make sure slings, chains, hooks, ramps, jacks and other

types of lifting devices are attached securely and have enough weight-

bearing capacity to lift or hold the machine safely. Always remain

aware of the location of other people in the area when lifting the

machine.

2.2.5 ALWAYS replace or repair electrical components with components

that are identical in rating and performance as the original component.

2.2.6 ALWAYS connect the safety chains.

WARNING

Safety Information Pump Packs

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2.3 Label Locations

10

Pump Packs Safety Information

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2.4 Safety and Operating Labels

Ref. Label Meaning/Label text

1 Center of gravity.

Note: This label is only on the DPP-M.

2 Consult Operator’s Manual!

Note: This label is only on the DPP-M.

3 Wear safety gloves!

Note: This label is only on the DPP-M.

4 Machine rating label.

This label indicates rating information for

the machine.

Note: This label is only on the DPP-M.

5 Hot surface hazard!

Note: This label is only on the DPP-M.

Safety Information Pump Packs

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6 Never connect the machine’s power cord to

an external power source. The power cord

MUST be conencted to the accessory

power receptacle complementary Ground

Heater™ machine.

7 Two persons are required to lift the

machine.

Note: This label is only on the DPP-M.

8 Weight/mass label:

This label indicates the total weight of the

machine.

Note: This label is only on the DPP-M.

9 Wear eye protection!

Note: This label is only on the DPP-M.

10 Electric shock hazard!

Note: This label is only on the DPP-M.

Ref. Label Meaning/Label text

LBS

KG

200

91

173608

Pump Packs Operation

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3. Operation

3.1 System Description

The Single Pump Pack (SPP) and Dual Pump Pack (DPP) are safe

and durable machines designed to expand the capacity and functions

of your Ground Heater™ machine.

The SPP consists of a ten foot leader hose and one positive

displacement pump encased in a durable enclosure. The DPP consists

of a ten foot leader hose and two positive displacement pumps

encased in a durable enclosure.

Each pump within the pump pack includes an individual pressure

gauge.

Each pump pack is designed to automatically shut down if the

complementary Ground Heater™ machine experiences a low level

fault.

Operation Pump Packs

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3.2 System Component Locations

Ref. Description Ref. Description

1 Enclosure 6 HTF discharge quick-connect

2 Manual lift handle 7 HTF pump one

3 Crane lift point 8 HTF filter

4 Heat Transfer Fluid (HTF) supply

quick-connect

9 Control panel

5 Pressure gauge 10 HTF pump two (DPP only)

SPP DPP

1

2

5

76

89 89

7

10

4

44

3

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6

Pump Packs Operation

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3.3 Control Panel

3.4 Positioning the Machine

Normal positioning and setup is as follows:

3.4.1 Position the machine on firm, dry, and level ground adjacent to your

Ground Heater™ machine.

Note: Position the machine, at most, ten feet from your Ground

Heater™ machine.

3.5 Preliminary Checks

Before starting the machine, check the following:

• Location—see section Positioning the Machine.

• Control switches—all must be in the OFF position.

• Hose connections—verify all hose connections are secured.

Ref. Description Ref. Description

a Pump one ON/OFF switch b Pump two ON/OFF switch (DPP)

SPP DPP

a a b

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Operation Pump Packs

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3.6 Connecting the Pump Pack to Your Ground Heater™ Machine

NOTICE: NEVER use this machine with anything other than the

intended complementary Ground Heater™ machine.

To connect the SPP or DPP to your Ground Heater™ machine, carry

out the following procedure:

3.6.1 Position the machine. See section Positioning the Machine.

3.6.2 Connect all supply and return hoses to the appropriate supply and

return quick-connect couplings on the Pump Pack and on your Ground

Heater™ machine. See your Ground Heater™ Operator’s Manual for

more information.

Note: Verify that all hose connections are secured before connecting

power to the machine.

3.6.3 Connect power to the machine. See section Connecting Power to the

Machine.

3.7 Connecting Power to the Machine

NOTICE: NEVER connect the machine to an external power source.

The machine MUST be connected to the accessory power receptacle

on the complementary Ground Heater™ machine. If an additional

Pump Pack is desired, an Auxiliary Pump Panel must be installed to

supply power to the additional machine.

To connect power to the machine, carry out the following procedure:

3.7.1 Verify that all hose connections are secured.

3.7.2 Position the machine. See section Positioning the Machine.

3.7.3 Connect the power cord to the accessory power receptacle on your

Ground Heater™ machine.

Pump Packs Operation

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3.8 Starting the Machine

NEVER use the Pump Pack machines to transfer any substance other

than Ground Heaters, Inc. Heat Transfer Fluid (HTF). Doing so could

result in personal injury, death, explosion, or damage to the machine.

Note: The Pump Pack machines are not designed to operate

independently. Each machine must be used in combination with a

Ground Heater™ machine.

3.8.1 Perform the necessary preliminary checks. See section Preliminary

Checks.

3.8.2 Start your Ground Heater™ machine. Refer to Ground Heater™

Operator’s Manual.

3.8.3 Warm the HTF. Refer to your Ground Heater™ Operator’s Manual.

3.8.4 Move the pump ON/OFF switch(es) to the ON position, one at a time.

Verify that:

• the pressure begins to build (monitor the pressure gauge(s) on

the Pump Pack)

• HTF is flowing (monitor the HTF flow indicator on your Ground

Heater™ machine)

3.8.5 Continue with normal operating procedures for your Ground Heater™

machine. Refer to Ground Heater™ Operator’s Manual.

3.9 Shutting Down the Machine

3.9.1 Move the pump ON/OFF switch(es) to the OFF position.

3.9.2 Allow the hoses and quick-connect couplings to cool for a minimum of

ten minutes.

3.9.3 Disconnect all hoses from the Pump Pack machine.

WARNING

Operation Pump Packs

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Notes:

Pump Packs Maintenance

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4. Maintenance

4.1 Periodic Maintenance Schedule

Before

and

after

each

use

Every

1200

hours

or

yearly

Inspect power cord for wear and damage



Inspect all hoses and connections for wear and

damage



Clean HTF strainer basket



Inspect HTF filter gaskets for wear and damage



Inspect strainer basket for wear and damage



Clean the quick-connect couplings



Maintenance Pump Packs

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4.2 Lifting, Transporting, and Storing the Machine

Two persons are required to manually lift the machine.

The machine may be lifted using the following methods:

• using a properly rated overhead lifting device such as a crane or

hoist

• using a properly rated forklift

• manual lift - requires two persons

4.2.1 To lift the machine using an overhead lifting device, use the hole on the

lifting bracket.

4.2.2 To lift the machine using a forklift, insert the forks at the indicated

locations.

During transportation, the machine must be properly secured using

chains, hooks, straps or other securing mechanisms.

During storage, verify that all ON/OFF switches are in the OFF

position.

WARNING

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Wacker Neuson DPP8.8, SPP4.4 User manual

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