Wacker Neuson E3000ES User manual

Operator’s Manual

Hydronic Surface Heater

E 2200

E 3000ES

Notice d’Emploi

Réchauffeur hydronique de surface

5000192803 04 0112

5000192803

EN / FR

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 Production Americas LLC.

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

Americas LLC 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 Production Americas LLC

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

Original

instructions

This Operator’s Manual presents the original instructions. The original language of this

Operator’s Manual is American English.

5000192779 03 0911

Foreword

wc_tx001665gb.fm 3

Foreword

Machines

covered by

this manual

This manual covers machines with the following item numbers:

Machine

documentation

 From this point forward in this documentation, Wacker Neuson Production

Americas LLC will be referred to as Wacker Neuson.

 Keep a copy of the Operator’s Manual with the machine at all times.

 Use the separate Parts Book supplied with the machine to order replacement

parts.

 If you are missing any of these documents, please contact Wacker Neuson to

order a replacement or visit www.wackerneuson.com.

 When ordering parts or requesting service information, be prepared to provide

the machine model number, item number, revision number, and serial number.

Expectations

for

information in

this manual

 This manual provides information and procedures to safely operate and

maintain the above Wacker Neuson model(s). For your own safety and to

reduce the risk of injury, carefully read, understand, and observe all instructions

described in this manual.

 Wacker Neuson expressly reserves the right to make technical modifications,

even without notice, which improve the performance or safety standards of its

machines.

 The information contained in this manual is based on machines manufactured

up until the time of publication. Wacker Neuson reserves the right to change

any portion of this information without notice.

Manufacturer’s

approval

This manual contains references to approved parts, attachments, and

modifications. The following definitions apply:

 Approved parts or attachments are those either manufactured or provided by

Wacker Neuson.

 Approved modifications are those performed by an authorized Wacker

Neuson service center according to written instructions published by Wacker

Neuson.

 Unapproved parts, attachments, and modifications are those that do not

meet the approved criteria.

Unapproved parts, attachments, or modifications may have the following

consequences:

 Serious injury hazards to the operator and persons in the work area

 Permanent damage to the machine which will not be covered under warranty

Machine Item Number Revision

E 2200 0620176 105 and above

E 2200 0620215 105 and above

E 2200G 0620216 110 and above

E 2200G 0620226 110 and above

E 3000ES 0620967 100 and above

E 3000ES-G 0620968 100 and above

Foreword

4 wc_tx001665gb.fm

Contact your Wacker Neuson dealer immediately if you have questions about

approved or unapproved parts, attachments, or modifications.

Table of Contents

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1

Foreword 3

1 Safety Information 9

1.1 Signal Words Used in this Manual ....................................................... 9

1.2 Machine Description and Intended Use ............................................. 10

1.3 Safety Guidelines for Operating the Machine ..................................... 11

1.4 Service Safety .................................................................................... 13

1.5 Safety Guidelines for Operating Combustion Burners ....................... 15

1.6 Safety Guidelines for Operating Gensets ........................................... 16

1.7 Safety Guidelines for Towing the Machine ......................................... 18

1.8 Safety Guidelines for Lifting the Machine ........................................... 19

2 Labels 20

2.1 Label Locations .................................................................................. 20

2.2 Label Meanings .................................................................................. 22

3 Lifting and Transporting 30

3.1 Lifting the Machine ............................................................................. 30

3.2 Hazardous Materials Placards ........................................................... 31

3.3 Preparing the Machine for Transport on a Truck or Trailer ................ 32

3.4 Transporting the Machine on a Truck or Trailer ................................. 33

3.5 Before Towing Checklist ..................................................................... 34

3.6 Towing the Machine ........................................................................... 35

3.7 Testing the Breakaway System (Electric Brakes) .............................. 36

4 Operation 38

4.1 Control / Component Locations .......................................................... 38

4.2 Control / Component Descriptions ..................................................... 39

4.3 Control Panel ...................................................................................... 40

4.4 Control Panel Components ................................................................ 41

4.5 Rear Components .............................................................................. 42

4.6 Pumps, Gauges, and Valves .............................................................. 43

4.7 Genset Control Panel ......................................................................... 44

4.8 Preparing the Machine for First Use ................................................... 45

4.9 Breaking in the Genset ....................................................................... 46

4.10 General Sequence of Operation ......................................................... 46

4.11 Checking the HTF Level ..................................................................... 47

4.12 Recommended Fuel ........................................................................... 48

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4.13 Refueling the Machine .........................................................................49

4.14 Positioning the Machine ......................................................................50

4.15 Pre-Starting Checks ............................................................................52

4.16 Connecting Power to the Machine ......................................................55

4.17 Starting and Stopping the Generator ...................................................56

4.18 Applying Power to the Machine ...........................................................57

4.19 Preheating the HTF .............................................................................58

4.20 Initiating HTF Flow ..............................................................................59

4.21 Setting the Operating Temperature .....................................................61

4.22 Positioning the Hoses and Operating the Machine .............................61

4.23 Monitoring the Operating Parameters .................................................63

4.24 Rewinding the Hoses ..........................................................................64

4.25 Shutting Down and Packing Up the Machine ......................................66

4.26 Resetting a Low HTF Level Fault ........................................................67

4.27 Quick-Connect Coupling Usage and Care ..........................................70

4.28 Resetting the Snap Switch ..................................................................71

4.29 Operating States of the Beckett Burner Controller ..............................72

5 Accessories 76

5.1 Available Accessories .........................................................................76

5.2 Connecting the HX 200 or HX 60 Heat Exchanger .............................77

5.3 Connecting the HX 100 or HX 30 Heat Exchanger .............................79

5.4 Connecting the HX 50 or HX 15 Heat Exchanger ...............................81

5.5 Combining the Machine with One HHS and One DPP ........................83

5.6 Combining the Machine with Two HHS and Two DPP (E 2200 only) .85

5.7 Mounting the Auxiliary Pump Panel ....................................................87

6 Burner Setup 88

6.1 Setting/Checking the Electrodes .........................................................91

6.2 Checking/Replacing the Burner Nozzle ...............................................93

6.3 Setting the “Z” Distance on V1-Style Heads ........................................95

6.4 Adjusting the Air Settings ....................................................................97

6.5 Setting the Fuel Pressure ....................................................................98

7 Maintenance 99

7.1 Periodic Maintenance Schedule ..........................................................99

7.2 Repairing a Hose ...............................................................................100

7.3 Inspecting the HTF System and the Fuel System .............................102

7.4 Inspecting Electrical Cords ................................................................103

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7.5 Filling the HTF Reservoir .................................................................. 104

7.6 Cleaning the HTF Strainer ................................................................ 107

7.7 Replacing the Fuel Filter .................................................................. 109

7.8 Lubricating the Hose Reel System ................................................... 110

7.9 Cleaning the Turbulators and the Exhaust Ducting .......................... 111

7.10 Inspecting/Replacing the Rope Gasket ............................................ 113

7.11 Removing the Burner ....................................................................... 114

7.12 Installing the Burner ......................................................................... 115

7.13 Storing the Machine ......................................................................... 116

7.14 Preparing the Machine for Seasonal Operation ............................... 117

7.15 Storing the Genset ........................................................................... 117

7.16 Connecting and Maintaining the Battery .......................................... 119

8 Genset Maintenance 121

8.1 Periodic Maintenance Schedule ....................................................... 121

8.2 Checking the Engine Oil ................................................................... 122

8.3 Changing the Engine Oil and Oil Filter ............................................. 123

8.4 Checking the Engine Coolant Level ................................................. 125

8.5 Cleaning the Spark Arrester ............................................................. 126

8.6 Replacing the Air Filter Element ....................................................... 127

8.7 Replacing Engine Fuel Filter ............................................................ 128

8.8 Changing Engine Coolant ................................................................ 130

8.9 Genset Shut-Down Codes ................................................................ 132

9 Troubleshooting 136

9.1 Troubleshooting the Machine ........................................................... 136

10 Technical Data 139

10.1 E 2200 .............................................................................................. 139

10.2 E 3000ES ......................................................................................... 140

10.3 Trailer ............................................................................................... 141

10.4 Dimensions ....................................................................................... 141

MSDS: Dowfrost™ HD 50 142

Fuji Temperature Controller 149

11 Schematics 152

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11.1 Electrical Schematic ..........................................................................152

11.2 Electrical Schematic Components .....................................................153

11.3 Burner System Circuit .......................................................................156

11.4 Circulation System Circuit .................................................................157

11.5 Rewind System Circuit ......................................................................158

11.6 Trailer Wiring .....................................................................................159

11.7 Trailer Plug — Wiring Diagram ..........................................................160

11.8 Trailer Junction Box — Wiring Diagram ............................................161

Avant-Propos 163

1 Informations sur la sécurité 165

1.1 Références d’appel se trouvant dans ce manuel ..............................165

1.2 Description de la machine et utilisation prévue .................................174

1.3 Sécurité d’utilisation ..........................................................................175

1.4 Sécurité lors de l’entretien .................................................................177

1.5 Consignes de sécurité pour l’utilisation des brûleurs à combustion ..179

1.6 Directives de sécurité pour opérer des groupes générateurs ...........180

1.7 Consignes de sécurité pour remorquer la machine ...........................182

1.8 Directives de sécurité pour soulever la machine ...............................183

2 Autocollants 184

2.1 Situation des autocollants .................................................................184

2.2 Signification des autocollants ............................................................186

3 Levage et transport 194

3.1 Levage de la machine .......................................................................194

3.2 Affiches de matières dangereuses ....................................................195

3.3 Préparation de la machine pour le transport .....................................196

3.4 Transport de la machine sur un camion ou une remorque ................197

3.5 Liste de vérification avant remorquage .............................................198

3.6 Remorquage de la machine ..............................................................199

3.7 Test du système de rupture (freins électriques) ................................200

4 Fonctionnement 202

4.1 Emplacement des commandes/composants .....................................202

4.2 Descriptions des commandes / composants .....................................203

4.3 Panneau de commande ....................................................................204

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4.4 Composants du panneau de commande ......................................... 205

4.5 Parties constituantes arrières ........................................................... 206

4.6 Pompes, jauges et valves ................................................................ 207

4.7 Panneau de commande de groupe générateur ................................ 208

4.8 Préparation de la machine à sa première utilisation ........................ 209

4.9 Rodage du groupe générateur ......................................................... 210

4.10 Ordre général des opérations ........................................................... 211

4.11 Vérification du niveau de FTC .......................................................... 212

4.12 Carburant recommandé ................................................................... 213

4.13 Ravitaillement en carburant de la machine ...................................... 214

4.14 Positionnement de la machine ......................................................... 216

4.15 Vérifications avant le démarrage ...................................................... 218

4.16 Brancher l’alimentation à la machine ............................................... 221

4.17 Démarrage et arrêt du générateur .................................................... 222

4.18 Application de la tension à la machine ............................................. 223

4.19 Préchauffage du FTC ....................................................................... 224

4.20 Initialisation de la circulation de FTC ................................................ 226

4.21 Réglage de la température de marche ............................................. 228

4.22 Positionnement des boyaux et fonctionnement de la machine ........ 229

4.23 Monitoring the Operating Parameters .............................................. 232

4.24 Enroulement des tuyaux ................................................................... 233

4.25 Arrêt et préparation de la machine pour le transport ........................ 235

4.26 Réinitialisation d’un problème de niveau bas de FTC ...................... 236

4.27 Couplage à raccord rapide, usage et précautions ............................ 239

4.28 Réinitialisation de l’interrupteur à rupture brusque ........................... 240

4.29 États de fonctionnement de la commande de brûleur Beckett ......... 241

5 Accessoires 246

5.1 Accessoires disponibles ................................................................... 246

5.2 Connexion de l’Échangeur thermique HX 200 ou HX 60™ .............. 247

5.3 Connexion de l’Échangeur thermique HX 100 ou HX 30 ................. 249

5.4 Connexion de l’Échangeur thermique HX 50 ou HX 15™ ................ 251

5.5 Combinaison de la machine avec un HHS et un DPP ..................... 253

5.6 Combinaison de la machine avec deux HHS et deux DPP

(E 2200 seulement) .......................................................................... 255

5.7 Montage du panneau de pompe auxiliaire ....................................... 258

6 Configuration du brûleur 259

6.1 Réglage/vérification des électrodes ................................................. 260

6.2 Vérification/remplacement de la buse de brûleur ............................. 262

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6.3 Réglage de la distance « Z » sur les têtes de style V1 .....................264

6.4 Ajustement du réglage d’air ...............................................................266

6.5 Ajustage de la pression du carburant ................................................267

7 Entretien 268

7.1 Plan d’entretien périodique ................................................................268

7.2 Entretien du tuyau .............................................................................270

7.3 Inspecter le système FTC et le système de carburant ......................272

7.4 Inspection des cordons et des branchements électriques ................273

7.5 Remplissage du réservoir de FTC .....................................................274

7.6 Nettoyage de la crépine du FTC .......................................................277

7.7 Remplacement du filtre à carburant ..................................................279

7.8 Lubrification du système du dévidoir enrouleur .................................280

7.9 Changement d’un turbulateur et nettoyage d’un tube de turbulateur 281

7.10 Inspection/remplacement du joint à corde .........................................283

7.11 Retrait du brûleur ...............................................................................285

7.12 Installation du brûleur ........................................................................286

7.13 Entreposage de la machine ...............................................................287

7.14 Préparation de la machine à une utilisation saisonnière ...................288

7.15 Remisage du groupe générateur .......................................................289

7.16 Branchement et entretien de la batterie ............................................290

8 Entretien du groupe électrogène 292

8.1 Plan d’entretien périodique ................................................................292

8.2 Vérification de l’huile moteur .............................................................293

8.3 Remplacement de l’huile moteur et du filtre à huile ..........................294

8.4 Vérification du niveau du liquide de refroidissement du moteur ........296

8.5 Nettoyage du pare-étincelles .............................................................297

8.6 Remplacement de l’élément filtrant ...................................................298

8.7 Remplacement du filtre à carburant du moteur .................................299

8.8 Changement du réfrigérant moteur ...................................................301

8.9 Codes d’arrêt de groupe générateur .................................................304

9 Recherche des pannes 308

9.1 Dépannage de la machine ................................................................308

10 Données techniques 312

10.1 E 2200 ...............................................................................................312

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10.2 E 3000ES ......................................................................................... 314

10.3 Remorque ......................................................................................... 315

10.4 Dimensions ....................................................................................... 316

MSDS: Dowfrost™ HD 50 317

Régulateur de température de Fuji 325

11 Schémas 328

11.1 Schéma électrique ............................................................................ 328

11.2 Schéma électrique - Parties Constituantes ...................................... 329

11.3 Circuit du système du brûleur ........................................................... 332

11.4 Circuit du système de circulation ...................................................... 333

11.5 Circuit du système de l’enrouleur ..................................................... 334

11.6 Câblage de la Remorque ................................................................. 335

11.7 Connecteur de remorque — Schéma de câblage ............................ 336

11.8 Boîte de jonction de la remorque — Schéma de câblage ................ 337

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8

E 2200 / E 3000ES Safety Information

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1 Safety Information

1.1 Signal Words Used in this Manual

This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE

signal words which must be followed to reduce the possibility of personal injury,

damage to the equipment, or improper service.

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

which, if not avoided, could result in property damage.

Note: A Note contains additional information important to a procedure.

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

f Obey all safety messages that follow this symbol.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death

or serious injury.

f To avoid death or serious injury from this type of hazard, obey all safety mes-

sages that follow this signal word.

WARNING

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

death or serious injury.

f To avoid possible death or serious injury from this type of hazard, obey all safety

messages that follow this signal word.

CAUTION

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

minor or moderate injury.

f To avoid possible minor or moderate injury from this type of hazard, obey all

safety messages that follow this signal word.

Safety Information E 2200 / E 3000ES

10 wc_si000540gb.fm

1.2 Machine Description and Intended Use

This machine is a hydronic surface heater. The Wacker Neuson Hydronic Surface

Heaters consist of trailer-mounted enclosures that house an optional diesel

generator, a hydronic heater, electric motors, fixed pump(s) and plumbing, a diesel

(or gas) burner, a fuel tank, and a hose handling system.

The hydronic heating system utilizes a burner that indirectly warms the Heat

Transfer Fluid (HTF). The warmed HTF is continuously circulated through a

vented, closed loop hose system. A positive displacement pump pushes the

warmed HTF through the hose system, thereby radiating and transferring the heat

to the required application area.

An insulated blanket may be laid over the hoses to increase efficiency. The low

HTF level protection device shuts down the machine if the HTF level drops below

minimum operational capacity.

This machine is intended to be used as a surface heater in order to thaw frozen

ground, to cure concrete, or to prevent frost and freezing. In addition, when used

with other Wacker Neuson accessories, this machine can be used to heat air.

This machine has been designed and built strictly for the intended use(s) described

above. Using the machine for any other purpose could permanently damage the

machine or seriously injure the operator or other persons in the area. Machine

damage caused by misuse is not covered under warranty.

The following are some examples of misuse:

 Using the machine to heat anything other than what is stated above

 Using the machine to pump anything other than the factory recommended Heat

Transfer Fluid

 Using the generator (if equipped) to power anything other than the machine

itself or Wacker Neuson accessory machines, as instructed in the Operator's

Manual

 Using the machine as a ladder, support, or work surface

 Using the machine to carry or transport passengers or equipment

 Using the machine to tow other machines

 Operating the generator (if equipped) in a manner that is inconsistent with all

federal, state, and local codes and regulations

 Operating the machine outside of factory specifications

 Operating the machine in a manner inconsistent with all warnings found on the

machine and in the Operator’s Manual

This machine has been designed and built in accordance with the latest global

safety standards. It has been carefully engineered to eliminate hazards as far as

practicable and to increase operator safety through protective guards and labeling.

However, some risks may remain even after protective measures have been taken.

They are called residual risks. On this machine, they may include exposure to:

 Heat, noise, and exhaust from the engine or hydronic heater

 Burns from the HTF or radiant heat from the hoses

 Fire hazards from improper refueling techniques

 Fuel and its fumes

E 2200 / E 3000ES Safety Information

wc_si000540gb.fm 11

 Personal injury from improper lifting of the trailer tongue

 Tripping hazards from the hoses

To protect yourself and others, make sure you thoroughly read and understand the

safety information presented in this manual before operating the machine.

1.3 Safety Guidelines for Operating the Machine

Operator

training

Before operating the machine:

 Read and understand the operating instructions contained in all manuals

delivered with the machine.

 Familiarize yourself with the location and proper use of all controls and safety

devices.

 Contact Wacker Neuson for additional training if necessary.

When operating this machine:

 Do not allow improperly trained people to operate the machine. People

operating the machine must be familiar with the potential risks and hazards

associated with it.

Operator

qualifications

Only trained personnel are permitted to start, operate, and shut down the machine.

They also must meet the following qualifications:

 have received instruction on how to properly use the machine

 are familiar with required safety devices

The machine must not be accessed or operated by:

 children

 people impaired by alcohol or drugs

Application

area

Be aware of the application area.

 Keep unauthorized personnel, children, and pets away from the machine.

 Remain aware of changing positions and the movement of other equipment and

personnel in the application area/job site.

Be aware of the application area.

 Do not operate the machine in areas that contain flammable objects, fuels, or

products that produce flammable vapors.

Safety

devices,

controls, and

attachments

Only operate the machine when:

 All safety devices and guards are in place and in working order.

 All controls operate correctly.

 The machine is set up correctly according to the instructions in the Operator’s

Manual.

 The machine is clean.

 The machine’s labels are legible.

To ensure safe operation of the machine:

Safety Information E 2200 / E 3000ES

12 wc_si000540gb.fm

 Do not operate the machine if any safety devices or guards are missing or

inoperative.

 Do not modify or defeat the safety devices.

 Only use accessories or attachments that are approved by Wacker Neuson.

Safe

operating

practices

When operating this machine:

 Remain aware of the machine’s moving parts. Keep hands, feet, and loose

clothing away from the machine’s moving parts.

When operating this machine:

 Do not operate a machine in need of repair.

Personal

Protective

Equipment

(PPE)

Wear the following Personal Protective Equipment (PPE) while operating this

machine:

 Close-fitting work clothes that do not hinder movement

 Safety glasses with side shields

 Hearing protection

 Safety-toed footwear

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wc_si000540gb.fm 13

1.4 Service Safety

Service

training

Before servicing or maintaining the machine:

 Read and understand the instructions contained in all manuals delivered with

the machine.

 Familiarize yourself with the location and proper use of all controls and safety

devices.

 Only trained personnel shall troubleshoot or repair problems occurring with the

machine.

 Contact Wacker Neuson for additional training if necessary.

When servicing or maintaining this machine:

 Do not allow improperly trained people to service or maintain the machine.

Personnel servicing or maintaining the machine must be familiar with the

associated potential risks and hazards.

Precautions

Follow the precautions below when servicing or maintaining the machine.

 Read and understand the service procedures before performing any service to

the machine.

 All adjustments and repairs must be completed before operation. Do not

operate the machine with a known problem or deficiency.

 All repairs and adjustments shall be completed by a qualified technician.

 Turn off the machine before performing maintenance or making repairs.

 Remain aware of the machine’s moving parts. Keep hands, feet, and loose

clothing away from the machine’s moving parts.

 Reinstall the safety devices and guards after repair and maintenance

procedures are complete.

Machine

modifications

When servicing or maintaining the machine:

 Use only accessories/attachments that are approved by Wacker Neuson.

When servicing or maintaining the machine:

 Do not defeat safety devices.

 Do not modify the machine without the express written approval of Wacker

Neuson.

Replacing

parts and

labels

 Replace worn or damaged components.

 Replace all missing and hard-to-read labels.

 When replacing electrical components, use components that are identical in

rating and performance as the original components.

 When replacement parts are required for this machine, use only Wacker

Neuson replacement parts or those parts equivalent to the original in all types of

specifications, such as physical dimensions, type, strength, and material.

Cleaning

When cleaning and servicing the machine:

 Keep the machine clean and free of debris such as leaves, paper, cartons, etc.

 Keep the labels legible.

Safety Information E 2200 / E 3000ES

14 wc_si000540gb.fm

When cleaning the machine:

 Do not clean the machine while it is running.

 Never use gasoline or other types of fuels or flammable solvents to clean the

machine. Fumes from fuels and solvents can become explosive.

Personal

Protective

Equipment

(PPE)

Wear the following Personal Protective Equipment (PPE) while servicing or

maintaining this machine:

 Close-fitting work clothes that do not hinder movement

 Safety glasses with side shields

 Hearing protection

 Safety-toed footwear

In addition, before servicing or maintaining the machine:

 Tie back long hair.

 Remove all jewelry (including rings).

Maintenance

guidelines

When maintaining the machine:

 Keep the fuel lines in good condition and properly connected.

 Allow the burner to cool before maintaining the machine.

 Allow the Heat Transfer Fluid (HTF) to cool before maintaining the machine.

 Keep all electrical cords away from heat, oil, vibrating surfaces, and sharp

edges.

E 2200 / E 3000ES Safety Information

wc_si000540gb.fm 15

1.5 Safety Guidelines for Operating Combustion Burners

Burner safety

When using the machine:

 Make sure you have proper certification or licensing required by the locality,

state, or province in which the machine is being installed to connect natural gas

or LP.

 Clean up any spilled fuel immediately.

 Replace the fuel tank cap after refueling the machine.

 Refill the fuel tank in a well-ventilated area.

When using the machine:

 Do not fill or drain the fuel tank near an open flame, while smoking, or while the

machine is running.

 Do not smoke when refueling the machine.

 Do not smoke when connecting natural gas or LP.

Note: Some machines may not be capable of supporting natural gas or LP. Please

see the burner manufacturer’s literature for more information.

DANGER

Exhaust gas from the burner contains carbon monoxide, a deadly poison. Exposure

to carbon monoxide can kill you in minutes.

f Never run the machine indoors or in an enclosed area unless the machine is

vented properly.

Safety Information E 2200 / E 3000ES

16 wc_si000540gb.fm

1.6 Safety Guidelines for Operating Gensets

This machine is built with user safety in mind; however, like any electrical device it

can present serious hazards if improperly operated and serviced. Follow

instructions carefully. Should questions arise during operation or service of this

equipment, contact your Wacker Neuson dealer.

General

precautions

 Keep a multi-class, type ABC or equivalent fire extinguisher at hand when using

the genset. Refer to NFPA No. 10 for further information regarding fire

extinguishers.

 Do not use evaporative starting fluids. They are highly explosive.

 Do not store items such as excess oil, oil rags, or tools within the genset

compartment. Items stored within the genset compartment are a fire hazard and

can restrict cooling air.

Before

operating the

genset

 Know how to start, operate, and stop the genset before starting it.

 Obtain the proper training for operating the genset. Do not allow untrained

personnel to operate or service the genset.

 Check the fuel lines and the fuel tank for leaks and cracks before starting the

engine.

 Clean the genset of any spilled fuel.

DANGER

Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES. Gen-

erator exhaust contains carbon monoxide (CO). This is a poison you cannot see or

smell. If you can smell the generator exhaust, you are breathing CO. But even if

you cannot smell the exhaust, you could be breathing CO.

WARNING

Electrocution hazard. Generators present special hazards during operation and

servicing. These include the risk of electrocution or severe electrical shock. Failure

to follow the safety information below can result in severe injury or death.

f Read and follow the safety instructions in this Operator’s Manual.

f Contact the genset manufacturer for additional information regarding the

genset.

WARNING

Internal combustion engines present special hazards during operation and fueling.

Failure to follow the warnings and safety instructions could result in severe injury or

death.

f Read and follow the safety instructions in this Operator’s Manual.

f Contact the genset manufacturer for additional information regarding the

genset.

E 2200 / E 3000ES Safety Information

wc_si000540gb.fm 17

Running the

genset

 Do not start the engine if fuel has spilled or a fuel odor is present.

 Keep the area around the exhaust pipe free of flammable materials.

 Do not smoke while operating the genset.

 Keep sparks, flames, electrical arcs, and other sources of ignition far away from

the genset.

 Do not touch the engine or muffler while the engine is running or immediately

after it has been turned off.

 Do not operate the genset with the maintenance covers off.

 Do not overload the genset. The total amperage of the tools and equipment

attached to the genset must not exceed the load rating of the genset.

 Do not operate the genset with wet hands.

 Do not remove the radiator cap when the genset is running or is hot.

Refueling

safety

When adding fuel to the fuel tank:

 Do not smoke.

 Do not refuel a hot or running engine.

When adding fuel to the fuel tank:

 Keep sparks, flames, electrical arcs, and other sources of ignition far away from

the genset.

 Refill the fuel tank only in a well-ventilated area.

 Reinstall the fuel tank cap after refueling.

Maintenance

safety

 Only a trained technician should attempt to repair the genset.

 Test procedures which require that the generator be running must be performed

using extreme caution.

 Make sure clothing and shoes are dry, stand on a dry wooden platform or rubber

insulating mat, and use tools with insulated handles when servicing the genset.

 Engine antifreeze is toxic to humans and animals. Clean up spills and dispose

of used engine antifreeze in accordance with local environmental regulations.

 Make sure all fasteners are secure and torqued properly.

Safety Information E 2200 / E 3000ES

18 wc_si000540gb.fm

1.7 Safety Guidelines for Towing the Machine

When towing the machine:

 Do not tow the machine if the towing vehicle’s hitch or the trailer’s coupler are

damaged.

 Do not tow the machine if any of the trailer’s lug nuts are missing.

 Do not tow the machine if the trailer’s tires have less than 1.5 mm (1/16 inch) of

tread.

 Do not tow the machine unless the trailer’s brakes are functioning properly.

 Do not exceed the trailer manufacturer’s speed limitations.

When towing the machine:

 Only tow the machine when the trailer’s lug nuts are properly torqued.

 Only tow the machine when the trailer’s tires are properly inflated.

 Only tow the machine when all trailer lights are functioning correctly.

 Only tow the machine when the trailer’s safety chains are connected to the

towing vehicle in a crisscross pattern.

 Maintain extra distance between the towing vehicle and other vehicles.

 Avoid soft shoulders, curbs, and sudden lane changes

 Abide by all licensing requirements for your area.

If you have not driven a towing vehicle with trailer before, practice turning,

stopping, and backing up the towing vehicle with trailer in an area away from traffic.

Only drive the towing vehicle with trailer when you are confident in your ability to do

so.

WARNING

Risk of severe injury or death. Improper trailer condition and towing technique can

lead to an accident.

f Obey the trailer manufacturer’s instructions and the instructions below to reduce

the risk of an accident.

E 2200 / E 3000ES Safety Information

wc_si000540gb.fm 19

1.8 Safety Guidelines for Lifting the Machine

When lifting the machine:

 Make sure slings, chains, hooks, ramps, jacks, forklifts, cranes, hoists, and any

other type of lifting device used is attached securely and has enough weight-

bearing capacity to lift or hold the machine safely. See section Technical Data

for machine weight.

 Remain aware of the location of other people when lifting the machine.

 Only use the lifting points and tie-downs described in the Operator’s Manual.

 Make sure the transporting vehicle has sufficient load capacity and platform size

to safely transport the machine.

To reduce the possibility of injury:

 Do not stand under the machine while it is being lifted or moved.

 Do not get onto the machine while it is being lifted or moved.

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20

Labels E 2200 / E 3000ES

2 Labels

2.1 Label Locations

wc_gr008049

626

1059

615

638

624

623

610

611

614

624

1060

1061

636

635

637

627

1055

615

625

618

619

620

621

606

639

601

624

1057

1053

1058

wc_si000541gb.fm

21

E 2200 / E 3000ES Labels

wc_gr008050

605

607

1053

602

603

1056

1058

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22

Labels E 2200 / E 3000ES

2.2 Label Meanings

601 Refer to back of connection box for further

connection details.

602 Stop!

Do not reset (until HTF leak is repaired and

HTF level is restored)

Red “LOW LEVEL FAULT” light on control

panel indicates HTF is below the minimum

operating level.

Follow procedure below to rectify the fault:

1. Shut off burner switch and pump

switch(es).

2. Find and repair the HTF leak.

3. Add HTF to reservoir up to “MIN” level on

HTF sight gauge.

4. Press manual reset button (below).

5. Turn on burner switch.

6. After burner ignites, turn on pump(s) one

at a time.

603 To prevent loss of Heat Transfer Fluid, the fill

valve must remain LOCKED SHUT (closed)

at all times except as directed in the Opera-

tor’s Manual.

604 Regularly inspect the rope gasket located

between the flue box and the heater vessel

for visual signs of combustion gas leakage.

Replace the gasket with part number P100-

312 when needed per the service manual.

CAUTION

REGULARLY INSPECT ROPE GASKET

BETWEEN FLUE BOX AND HEATER

VESSEL FOR VISUAL SIGNS OF

COMBUSTION GAS LEAKAGE. REPLACE

GASKET WITH GHI#P100-312 PER

GROUND HEATERS SERVICE MANUAL.

168493

wc_si000541gb.fm

23

E 2200 / E 3000ES Labels

605 Turn the handle clockwise to engage the

hose reel brake.

Turn the handle counterclockwise to release

the hose reel brake.

606 Approximately 3.4 gallons (U.S.) is repre-

sented by each inch of fuel observed in the

fuel gauge.

607 Heat Transfer Fluid level. This label indicates

the minimum and maximum level for the

Heat Transfer Fluid. This label is located

adjacent to a sight gauge on the Heat Trans-

fer Fluid reservoir.

610 Plug in the strobe light to this side of the

receptacle.

611 Plug in the Pump Pack to this side of the

receptacle.

614 —

BRAKE

ENGAGE

DISENGAGE

DISENGAGEBRAKE

BEFORE REWINDING

APPROXIMATELY 3.4 GALLONS (U.S.) IS

REPRESENTED BY EACH INCH OF FUEL

OBSERVED IN THE FUEL GAUGE

MAX

MIN

wc_si000541gb.fm

24

Labels E 2200 / E 3000ES

615 WARNING:

Read Operator’s Manual before operating

machine. Exhaust gas is deadly. Operate

machine only in well ventilated area. Do not

operate machine indoors.

618 WARNING!

Hot fluids: gloves required.

Eye protection required.

Never loosen or remove hoses or operate

valves while pump is running.

Never loosen or remove hoses or operate

valves while heater is running.

Never loosen or remove hoses while fluid is

above 100 F (212 C).

Safety caps are screwed on to all hose bibbs

and valves which do not have factory

installed hoses attached. Never loosen or

remove a safety cap while fluid is above

100 F (212 C). Only remove a safety cap

in order to attach a hose. Do not operate

machine with safety caps missing.

Failure to heed these warnings could result

in serious burns and other personal injury to

operator or bystanders.

619 WARNING

Hose rewind mechanism

1. Do not operate without guard in place.

2. Do not wear loose clothing.

3. When operating hose rewind mechanism,

place foot pedal control on dry ground at

least 4 feet behind the machine.

4. Keep hands and clothing clear of the

hose reel, chain, and sprockets.

Failure to do so could result in serious injury

to operator or bystanders.

W A R N I N G

wc_si000541gb.fm

25

E 2200 / E 3000ES Labels

620 WARNING!

Before operating this Ground Heater™, read

and fully understand the Operator’s Manual.

Failure to do so could result in serious injury

to the operator or bystander(s).

621

DANGER!

Electric shock hazard.

Connect only to a grounded, GFI-protected

power source.

Position machine on the site such that nei-

ther the machine or the operator is standing

in water.

When operating hose rewind mechanism,

place foot pedal control on dry ground.

Failure to do so could result in serious injury

or death.

623 WARNING:

Lugnuts factory torqued to 110 ft.lbs. Verify

lugnuts are properly torqued before trans-

porting. Failure to heed above warning could

result in wheel loss which can cause injury or

death.

624 Tie-down point.

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26

Labels E 2200 / E 3000ES

625 WARNING!

Jack should not be deployed for truck bed

transport. Properly support tongue with wood

block and retract jack before tightening

chains or straps. Jack is not designed to take

loads that ratcheting straps or load binded

chains can deliver. Use jack for raising or

lowering trailer tongue only. Failure to heed

these warnings could result in damage to

personal property or cause serious injury or

death.

626

627 WARNING:

Attach chains or straps only to axles and

designated “tie-down” points. Never run

straps across any surface on this machine

which is painted red. Failure to heed above

warning could result in damage to personal

property or cause serious injury or death.

635 Do not use ether or other start helpers on

generator engine. Failure to heed the above

warning may cause irreparable damage and

void engine warranty.

636 Read Operator’s Manual. Follow use and

maintenance guidelines as recommended by

generator manufacturer and engine manu-

facturer. Failure to do so may cause irrepara-

ble damage and void engine or generator

warranty.

For machines powered by

the generator:

Use a 50-50 blend of #2 diesel

and #1 diesel plus additives,

or a 50-50 blend of #2 diesel

and K1 kerosene plus addi-

tives when temperatures

are below 5°F (-15°C).

Use a 70-30 blend of #2 diesel and #1 diesel plus additives or

a 70-30 blend of #2 diesel and K1 kerosene plus additives

when temperatures are in the range 5 to 25°F (-15 to -4°C).

Use a winter-blend diesel when temperatures are above

25°F (-4°C).

For machines powered by

the power utility:

Use 100% #1 diesel plus

additives or 100% K1 kero-

sene plus additives when

temperatures are below

are below 5°F (-15°C).

wc_gr008377

WARNING

Attach Chains or Straps ONLY to Axles and

Designed "TIE DOWN" Points

168577

Never Run Straps Across Any Surface on this

Machine Which is Painted RED.

Failure to heed above warning could result in damage to

personal property or cause serious injury or death.

CAUTION

DO NOT USE ETHER OR OTHER START

HELPERS ON GENERATOR ENGINE

Failure to heed the above warning may cause

irreparable damage and void engine warranty.

168574

WARNING

READ OPERATOR MANUAL

168575

FOLLOW USE AND MAINTENANCE GUIDELINES

AS RECOMMENDED BY GENERATOR

MANUFACTURER AND ENGINE MANUFACTURER

Failure to do so may cause irreparable damage

and void engine or generator warranty.

wc_si000541gb.fm

27

E 2200 / E 3000ES Labels

637 Warranty claims with respect to generator set

are to be submitted to generator manufac-

turer. For assistance on all generator set

issues (engine is warranted through Onan,

not Kubota) contact Onan at 800-888-ONAN

or www.onan.com. to locate nearest autho-

rized distributor.

638 Machine rating label: This label indicates rat-

ing information for the machine.

639 Burner setup.

This label indicates important setup informa-

tion for the burner.

1053 CAUTION!

Hot surface hazard!

1055 HTF MSDS label.

This label is the Material Safety Data Sheet

for the HTF installed in the factory.

1056 THIS HEATER OPERATES AT ZERO

(ATMOSPHERIC) PRESSURE AND IS NOT

SUBJECT TO REGULATIONS APPLICA-

BLE TO PRESSURIZED “BOILERS”.

wc_si000541gb.fm

28

Labels E 2200 / E 3000ES

— A nameplate listing the model number, item

number, revision number, and serial number

is attached to each unit. Please record the

information found on this plate so it will be

available should the nameplate become lost

or damaged. When ordering parts or

requesting service information, you will

always be asked to specify the model num-

ber, item number, revision number, and serial

number of the unit.

1058 DANGER

Asphyxiation hazard.

Using a Hydronic Surface Heater indoors

CAN KILL YOU IN MINUTES. Generator and

burner exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

Never use inside an enclosed area even if

doors and windows are open.

Only use outside away from windows, doors,

and vents.

Read manual before use.

1059 CAUTION

This machine uses diesel fuel.

1060 (on trailer)

Tire and loading information label:

This label indicates tire and loading informa-

tion for the trailer.

1061 (on trailer)

VIN label. This label displays vehicle identifi-

cation numbers and other related informa-

tion.

DIESEL

CAUTION

VORSICHT

PRECAUCION

The weight of cargo should never exceed

wc_si000541gb.fm

29

E 2200 / E 3000ES Labels

xx Never operate in an explosive environment

or near flammable vapors, fuels or combusti-

bles. Explosion or fire may occur. Risk of

severe injury or death.

5200002911

Never operate in an explosive environment or near flammable vapors, fuels

or combustibles. Explosion or fire may occur. Risk of severe injury or death.

Nunca opere en un ambiente explosivo o cerca de los vapores inflamables,

gasolina o combustibles. Explosión o un incendio puede ocurrir.

Riesgo de lesiones graves o la muerte.

Ne faire jamais fonctionner dans un environnement explosif ou à proximité

des vapeurs inflammables, des carburants ou combustibles. Explosion ou un

incendie peut se produire. Risque de blessures graves ou la mort.

WARNING

ADVERTENCIA

AVERTISSEMENT

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30

Lifting and Transporting E 2200 / E 3000ES

3

Lifting and Transporting

3.1 Lifting the Machine

Requirements

 Lifting device (crane or hoist) capable of supporting the machine’s weight

 Lifting hooks and chains capable of supporting the machine’s weight

 Machine stopped, cooled, and accessories removed. See section Shutting

Down and Packing Up the Machine.

Procedure

Perform the procedure below to lift the machine.

1. Only those machines fitted with optional lifting bails may be lifted with a crane.

Attach the lifting hook and chain from the crane to one of the lifting eyes (a) on

the machine.

2. Lift the machine a short distance.

3. Check for stability. If necessary, lower the machine and reposition it. Only

continue lifting when the machine is stable.

4. Continue lifting the machine as necessary.

WARNING

Crushing hazard. You may be crushed if the lifting devices fail.

f Never stand under, or get onto, the machine while it is being lifted or moved.

f Use only the designated lifting points to lift the machine.

wc_gr008053

a

wc_tx001666gb.fm

31

E 2200 / E 3000ES Lifting and Transporting

3.2 Hazardous Materials Placards

Hazardous

materials

placards

The Pipeline and Hazardous Materials Safety Administration (PHMSA) requires

that hazardous materials placards be placed on this machine when transporting it

unless the fuel tank has been drained and purged of all fuel and residue.

Before transporting the machine:

1. Drain and purge the fuel tank of all fuel and fuel residue OR place placards that

display the numeric hazardous material code for diesel fuel on three sides of the

machine.

Note: The placards are included with the machine.

2. Consult the Department of Transportation (DOT), or equivalent agency, in the

states or countries in which this machine is to be transported, regarding:

 Driver’s licensing requirements for transporting machines that bear hazard-

ous materials placards

 Other restrictions for use of this machine

Note: This applies to the E 2200 only.

wc_tx001666gb.fm

32

Lifting and Transporting E 2200 / E 3000ES

3.3 Preparing the Machine for Transport on a Truck or Trailer

Requirements

 Machine stopped. See topic Shutting Down and Packing Up the Machine.

 Flatbed truck or trailer capable of supporting the machine’s weight.

 Chains, hooks, or straps capable of supporting the machine’s weight.

Checklist

Before transporting the machine, check the following items:

Machine

 Check that the hoses are completely wound on the hose reel and that all hose

ends are secured.

 Check that all accessories are securely stored within the machine.

 Check that all doors and access panels of the machine are closed.

 Check that all electrical supplies are disconnected from the machine.

 For machines with external fuel supplies, check that all fuel supplies are

disconnected from the machine.

 For machines with gensets, check that the genset engine is stopped.

Loading and transporting equipment

 Check that the transport vehicle or trailer can support the weight of the machine.

 Check that the transport vehicle or trailer is wide enough to support the

machine.

 Check that the wheels of the transport vehicle or trailer are chocked during the

loading process.

 Check that the transport vehicle or trailer is clean and free of grease, oil, ice,

and other loose material.

 Check that any ramps used in the loading process:

 Can support the weight of the machine

 Are clean and free of grease, oil, ice, and other loose material.

 Are securely connected to the transport vehicle or trailer.

 Are of sufficient length to keep the loading angle 15° or less.

In addition:

 Check that the loading area is flat and the ground is stable.

 Check the overall height of the machine once loaded. Plan your travel route so

there will be adequate clearance for overpasses, road signs, buildings, etc.

 Check local regulations regarding transporting and obey these regulations.

WARNING

Crushing hazard. Improperly securing the machine can lead to a crushing hazard.

f Use only the designated tie-down points to secure the machine to a truck or

trailer.

wc_tx001666gb.fm

33

E 2200 / E 3000ES Lifting and Transporting

3.4 Transporting the Machine on a Truck or Trailer

Requirements

 Machine stopped

 All doors and access covers closed and secured

 Properly-rated ramps or docks

 Properly-rated chains or straps

NOTICE: Do not run chains or straps across any painted surface. Failure to com-

ply may cause damage to your machine.

Procedure

Perform the procedure below to transport on a flat bed truck or trailer.

1. Move the machine onto the flat bed truck using properly-rated ramps or docks.

2. Install a support (a) under the trailer tongue.

NOTICE: Do not use the trailer jack to support the machine during transport.

3. Rotate the trailer jack (b) to the horizontal position or raise it.

4. Secure the machine to the bed with properly-rated chains or straps (d).

5. Install chocks (e) under the wheels.

Result

The machine is ready to be transported.

WARNING

Crushing hazard. Improperly securing the machine can lead to a crushing hazard.

f Use only the designated tie-down points to secure the machine.

wc_gr008640

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Wacker Neuson E3000ES, E2200 User manual

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