Wacker Neuson E700M User manual

Operator’s Manual

Hydronic Surface Heater

E 700M

0171730EN

0171730en / 003

Foreword

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Foreword

Machines

covered by

this manual

This manual covers machines with the following item numbers:

Machine

documentation

 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

Corporation 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 Corporation 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 Corporation reserves the right to

change any portion of this information without notice.

Copyright

notice

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

 This publication may be reproduced through photocopying 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, and violators will be

prosecuted.

Trademarks

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

owners.

Machine Item Number

E 700M 0620243

E 700M 0620214

E 700M 0620195

Foreword

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Table of Contents

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Foreword 3

1. Safety Information 7

1.1 Operating Safety .................................................................................. 8

1.2 Operator Safety while using Combustion Burners ............................... 9

1.3 Operator Safety while using Generators ............................................ 10

1.4 Service Safety .................................................................................... 11

1.5 Label Locations .................................................................................. 12

1.6 Safety and Operating Labels .............................................................. 12

2 Lifting, Transporting, and Storing 17

2.1 Lifting the Machine ............................................................................. 17

2.2 Transporting the Machine ................................................................... 18

2.3 Storing the Machine ........................................................................... 19

2.4 Preparing the Machine for Seasonal Operation ................................. 20

3. Operation 21

3.1 System Description ............................................................................ 21

3.2 System Component Locations ........................................................... 22

3.3 Positioning the Machine ..................................................................... 24

3.4 Recommended Fuels ......................................................................... 25

3.5 Control Panel ...................................................................................... 26

3.6 Preliminary Checks ............................................................................ 28

3.7 Starting the Generator ........................................................................ 29

3.8 Starting the Machine .......................................................................... 30

3.9 Warming the Hoses ............................................................................ 31

3.10 Filling the Hoses ................................................................................. 32

3.11 Unwinding and Positioning the Hoses ................................................ 33

3.12 Monitoring the Operating Parameters ................................................ 34

3.13 Shutting Down the Machine at End of Day ......................................... 35

3.14 Shutting Down and Restarting the Machine During Operation ........... 36

3.15 Rewinding the Hose ........................................................................... 37

3.16 Adjusting the Burner Air Setting ......................................................... 38

3.17 Shutting Down the Generator ............................................................. 39

3.18 Application Capacities ........................................................................ 40

Table of Contents

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4. Accessories 41

4.1 Available Accessories .........................................................................41

4.2 Combining the Machine with One Heat Exchanger .............................42

4.3 Combining the Machine with Two Heat Exchangers ...........................43

4.4 Combining the Machine with Four Heat Exchangers ..........................44

4.5 Combining the Machine with One HHS and One DPP ........................45

5. Maintenance 47

5.1 Periodic Maintenance Schedule ..........................................................47

5.2 Cleaning the HTF Strainer Basket .......................................................48

5.3 Replenishing the HTF ..........................................................................50

5.4 Checking the Fuel Pressure ................................................................51

5.5 Removing the Burner ..........................................................................52

5.6 Replacing the Burner Nozzle ...............................................................54

5.7 Checking and Adjusting the Burner Electrodes ...................................56

5.8 Burner Adjustments .............................................................................58

5.9 Replacing the Genset Fuel Filter .........................................................60

5.10 Replacing the Genset Air Filter ...........................................................62

5.11 Changing the Genset Oil and Filter .....................................................63

5.12 List of Abbreviations ............................................................................64

5.13 Troubleshooting ...................................................................................65

5.14 Electrical Schematic (Page 1) .............................................................68

5.15 Electrical Schematic (Page 2) .............................................................69

6. Technical Data 70

6.1 E700M Technical Data ........................................................................70

E700M Safety Information

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1. 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

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

Note: Contains additional information important to a procedure.

DANGER

WARNING

CAUTION

Safety Information E700M

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1.1 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 run the machine indoors or in an enclosed area unless

adequate ventilation, through such items as exhaust fans or hoses, is

provided. Exhaust gas from the genset and from the burner contains

carbon monoxide, a deadly poison. Exposure to carbon monoxide

WILL KILL YOU IN MINUTES.

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

tip, roll, slide, or fall while operating.

1.1.2 NEVER start a machine in need of repair.

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

machine.

1.1.4 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.

1.1.5 DO NOT smoke while operating the machine.

1.1.6 ALWAYS refer to the applicable Department of Transportation

regulations before towing.

1.1.7 NEVER transport people in or on the machine.

1.1.8 ALWAYS wear gloves when handling duct work and hot components.

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

fuels, or products that produce flammable vapors.

WARNING

E700M Safety Information

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1.2 Operator Safety while using Combustion Burners

Combustion burners present special hazards during operation and

fueling. Read and follow the warning instructions in the burner owner’s

manual and the safety guidelines below. Failure to follow the warnings

and safety guidelines could result in severe injury or death.

NEVER run the machine indoors or in an enclosed area unless

adequate ventilation, through such items as exhaust fans or hoses, is

provided. Exhaust gas from the genset and from the burner contains

carbon monoxide, a deadly poison. Exposure to carbon monoxide

WILL KILL YOU IN MINUTES.

1.2.1 DO NOT fill or drain the fuel tank near an open flame, while smoking,

or while the engine is running.

1.2.2 ALWAYS refill the fuel tank in a well-ventilated area.

1.2.3 ALWAYS replace the fuel tank cap after refueling.

1.2.4 DO NOT spill fuel when refueling the machine. Clean up spilled fuel

immediately.

1.2.5 DO NOT refuel a hot or running machine.

WARNING

Safety Information E700M

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1.3 Operator Safety while using Generators

NEVER run the machine indoors or in an enclosed area unless

adequate ventilation, through such items as exhaust fans or hoses, is

provided. Exhaust gas from the genset and from the burner contains

carbon monoxide, a deadly poison. Exposure to carbon monoxide

WILL KILL YOU IN MINUTES.

1.3.1 NEVER operate the generator when the cooolant level is low. Failure

to comply could cause serious damage to the machine.

1.3.2 NEVER operate the generator when open containers of fuel, paint, or

other flammable liquids are near.

1.3.3 NEVER overload the generator. The total amperage of the tools and

equipment attached to the generator must not exceed the load rating

of the generator.

1.3.4 NEVER operate the generator, or tools attached to the generator, with

wet hands.

1.3.5 NEVER allow untrained personnel to operate or service the generator.

The generator set should be set up by a certified electrician.

1.3.6 NEVER touch the hot engine, exhaust, or generator components.

Burns will result.

1.3.7 ALWAYS follow starting and stopping instructions described in this

manual. Know how to operate and stop generator before starting it.

1.3.8 DO NOT start the engine if fuel has spilled or a fuel odor is present.

Move the generator away from the spill and wipe the generator dry

before starting.

1.3.9 DO NOT pressure wash the control panel, generator end, or any other

electrical components when cleaning the unit. Never allow water to

accumulate around the base of the generator set. If water is present,

DO NOT service!

WARNING

E700M Safety Information

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1.4 Service 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.

1.4.1 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.

1.4.2 ALWAYS replace the safety devices and guards after repairs and

maintenance.

1.4.3 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.

1.4.4 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.

1.4.5 ALWAYS replace or repair electrical components with components

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

1.4.6 ALWAYS check the tires on the trailer for tread wear, inflation, and

condition. Replace worn tires.

1.4.7 ALWAYS connect the safety chains.

1.4.8 ALWAYS make sure directional and trailer lights are connected and

working properly.

1.4.9 ALWAYS check that the lug nuts holding the wheels are tight and that

none are missing.

WARNING

Safety Information E700M

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1.5 Label Locations

1.6 Safety and Operating Labels

Ref. Label Meaning

1 Hand Entanglement hazard. Mov-

ing parts can crush and cut. Do not

operate with guard removed.

2 Hot surface hazard.

3 Electric shock hazard.

E700M Safety Information

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4 Wear safety gloves.

5 Wear eye protection.

6 Consult Operation Manual.

7 Warning: Electrical shock hazard.

Read Operator’s Manual.

8 Caution: Only diesel fuel may be

used in this machine.

Ref. Label Meaning

D

DIESEL

CAUTION

VORSICHT

PRECAUCION



Safety Information E700M

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9 Hose reel brake label. This label

indicates information regarding the

operation of the hose reel brake

assembly.

10 Maximum power rating. This label

indicates the maximum power out-

put for the convenience receptacle.

11 Heat transfer fluid level. This label

indicates the minimum and maxi-

mum level for the heat transfer fluid.

This label is located adjacent to a

sight gauge on the heat transfer

fluid reservoir.

12 Weight/mass label. Indicates the

total weight of the machine, includ-

ing the trailer and a full fuel tank.

Ref. Label Meaning

E700M Safety Information

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13 Start. This label indicates a start

button. For more information on this

control, see the Operator Controls

section in this manual.

14 Rating plate. This label gives

information about the machine.

15 Coolant level label. This label

indicates the maximum hot and

minimum cold level for the coolant

on the generator.

16 Tie-down point.

Ref. Label Meaning

Safety Information E700M

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Notes:

E 700M Lifting, Transporting, and Storing

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2 Lifting, Transporting, and Storing

2.1 Lifting the Machine

Prerequisites

 Lifting device (crane or hoist) capable of supporting 3200 kg (7055 lbs.)

 Lifting hooks and chains capable of supporting 3200 kg (7055 lbs.)

 Machine stopped, cooled, and broken down. See section Shutting Down the

Machine at End of Day.

Procedure

Follow the procedure below to lift the machine.

1. Attach the lifting device to one of the lifting eyes (a) on the machine using hooks

or shackles.

2. Attach the other end of the chains to the lifting equipment.

3. Lift the machine a small distance.

4. Check for stability. If necessary, lower the machine, reposition the lifting device,

and lift the machine a small distance again.

5. 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.

Lifting, Transporting, and Storing E 700M

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2.2 Transporting the Machine

Prerequisites

 Lifting equipment (crane, hoist, or fork truck) capable of supporting 3200 kg

(7055 lbs.)

 Lifting hooks and chains capable of supporting 3200 kg (7055 lbs.)

 Transportation mechanism (truck, flatbed, or other) capable of supporting or

towing 3200 kg (7055 lbs.)

NOTICE: Your machine may include a factory installed trailer. If so, you must

attach the machine to a truck with a towing capacity of 3200 kg (7055 lbs.) or

greater.

Procedure

1. If necessary, lift the machine onto the transportation mechanism. See section

Lifting the Machine.

2. Secure the machine using properly rated straps, chains, or other mechanisms

attached at the four labeled tie down locations.

3. Verify that all hoses are completely wound on the hose reel and that all hose

ends are adequately secured.

4. Verify that all access doors and panels are properly secured.

5. Transport 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.

E 700M Lifting, Transporting, and Storing

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2.3 Storing the Machine

Short term

storage

1. Stop and break down the machine. See section Stopping and Breaking Down

the Machine.

2. Remove and store any accessories.

3. Allow the heater to cool sufficiently.

4. Verify that all control switches are in the Off position.

5. If necessary, fill the HTF reservoir.

6. If necessary, fill the fuel tank.

Long-term

storage

1. Fill fuel tank with stabilized fuel and operate the burner for at least fifteen

minutes to ensure circulation through entire fuel system. Any brand of fuel

stabilizer is acceptable.

2. Allow heater to cool sufficiently. Cover the chimney and the burner with plastic

wrap or other waterproof material. This will prevent corrosive moisture build-up

and blockages caused by animal nests.

3. If applicable, remove the emergency break-away battery and store the battery in

a cool, dry place. Connect battery to a trickle charger once every 30 days to

maintain full charge.

4. Shut and lock all doors.

5. If applicable, protect the trailer tires from direct sun light.

6. When removing from storage, the machine must be prepared for operation. See

section Preparing the Machine for Seasonal Operation.

Lifting, Transporting, and Storing E 700M

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2.4 Preparing the Machine for Seasonal Operation

Prerequisites

Machine removed from storage.

Background

After removing the machine from long term storage, it must be prepared for

operation. This page indicates the procedures that must be performed before each

seasonal use.

Machine

 Remove any protective coverings from the chimney and burner.

 Clean all enclosures.

Heater

 Remove any carbon buildup from the heater and burner assemblies.

 Replace the burner nozzle. See section Replacing the Burner Nozzle.

 Verify burner electrode position. See section Checking and Adjusting the

Burner Electrodes.

 Verify fuel pump pressure. See section Burner Adjustments.

 Verify burner combustion quality. See section Burner Adjustments.

Electrical

Systems

 Inspect all wires for damage, corrosion, or wear. Replace if necessary.

 Inspect all controls for damage, corrosion, or wear. Replace if necessary.

 Verify that the intended power source is properly rated. See section Technical

Data for power requirements.

Fluid Systems

 Inspect all hoses and couplings for wear or damage. Replace if necessary.

 Clean the HTF strainer basket. See section Cleaning the HTF Strainer Basket.

 Replace the fuel filter element.

Your machine is now prepared for seasonal operation. Continue to section

Positioning the Machine.

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Wacker Neuson E700M User manual

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