Wacker Neuson E5000 User manual

Operator’s Manual

Hydronic Surface Heater

E5000

Type E5000

Document 5000193536

Date 1115

Revision 06

Language EN

5000193536

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.

Foreword

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Foreword

This heater is designed and approved for use as a construction heater in

accordance with Standard ANSI Z83.7–CSGA 2.14. CHECK WITH YOUR LOCAL

FIRE SAFETY AUTHORITY IF YOU HAVE QUESTIONS ABOUT APPLICATIONS.

Other standards govern the use of fuel gases and heat producing products in

specific applications. Your local authority can advise you about these.

THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE

REGULATIONS OF THE AUTHORITIES HAVING JURISDICTION.

WARNING

Risk of personal injury or machine damage from improper use.

f Before using the machine, read and understand all instructions and follow them

carefully.

f The manufacturer is not responsible for damages to goods or persons due to

improper use of this machine.

WARNING

Failure to comply with the precautions and instructions provided with this machine

can result in death, serious injury, and property loss or damage from fire, explosion,

burns, asphyxiation, carbon monoxide poisoning, and/or electric shock.

f Before using the machine, read and understand all precautions and instructions

that have been provided. Follow them carefully.

f Only persons who can understand and follow the precautions and instructions

should use or service this machine.

f Contact the manufacturer if you need assistance with operating the machine or

need replacement manuals or labels.

WARNING

Work site fire, burn, inhalation, and explosion hazards.

f Keep solid combustibles, such as building materials, paper, or cardboard at a

safe distance away from the machine as recommended by the instructions.

f Never use this machine in spaces which do or may contain volatile or airborne

combustibles, or products such as gasoline, solvents, paint thinner, dust parti-

cles, or unknown chemicals.

WARNING

Not for use in homes or recreational vehicles. Installing this machine in a home or

RV may result in fire, explosion, property damage, personal injury, or death.

f Operate the machine only for applications specified in Machine Description and

Intended Use.

Foreword

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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

Contact your Wacker Neuson dealer immediately if you have questions about

approved or unapproved parts, attachments, or modifications.

Machine Item Number

E 5000 (oil)

E 5000 (gas)

E 5000 (oil & generator)

0620897

0620898

0620899

Foreword

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CALIFORNIA

Proposition

65 Warning:

Diesel engine exhaust, some of its constituents, and certain vehicle components,

contain or emit chemicals known to the State of California to cause cancer and

birth defects or other reproductive harm.

Foreword

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Table of Contents

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Foreword 3

1 Safety Information 13

1.1 Signal Words Used in this Manual ..................................................... 13

1.2 Machine Description and Intended Use ............................................. 14

1.3 Safety Guidelines for Operating the Machine ..................................... 16

1.4 Service Safety .................................................................................... 18

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

1.6 Safety Guidelines for Operating Gensets ........................................... 20

1.7 Safety Guidelines for Operating Combustion Burners ....................... 22

1.8 Safety Guidelines for Towing the Machine ......................................... 23

1.9 Reporting Safety Defects ................................................................... 24

2 Labels 26

2.1 Label Locations .................................................................................. 26

2.2 Label Meanings .................................................................................. 27

3 Lifting and Transporting 34

3.1 Lifting the Machine ............................................................................. 34

3.2 Hazardous Materials Placards ........................................................... 36

3.3 Preparing the Machine for Transport on a Truck or Trailer ................ 37

3.4 Transporting the Machine on a Flat Bed ............................................ 38

3.5 Before Towing Checklist ..................................................................... 40

3.6 Towing the Machine ........................................................................... 41

3.7 Testing the Breakaway System (Electric Brakes) .............................. 42

4 Operation 45

4.1 System Description ............................................................................ 45

4.2 External Components ......................................................................... 46

4.3 Internal Components .......................................................................... 47

4.4 Rear Components .............................................................................. 48

4.5 Pumps, Gauges, and Valves .............................................................. 49

4.6 Control Panel ...................................................................................... 50

4.7 Control Panel Components ................................................................ 51

4.8 Genset Control Panel ......................................................................... 52

4.9 General Sequence of Operation ......................................................... 53

4.10 Preparing the Machine for First Use ................................................... 53

4.11 Breaking in the Genset ....................................................................... 54

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4.12 Checking the HTF Level ..................................................................... 55

4.13 Recommended Fuel ........................................................................... 56

4.14 Checking the Fuel Level ..................................................................... 57

4.15 Positioning the Machine ...................................................................... 58

4.16 Pre-Starting Checks ............................................................................ 60

4.17 Connecting Power to the Machine ...................................................... 62

4.18 Starting and Stopping the Generator .................................................. 63

4.19 Applying Power to the Machine .......................................................... 64

4.20 Preheating the HTF ............................................................................ 65

4.21 Initiating the HTF Flow ........................................................................ 66

4.22 Setting the Operating Temperature .................................................... 68

4.23 Unwinding and Positioning the Hoses ................................................ 69

4.24 Using the Temperature Gauges ......................................................... 73

4.25 Monitoring the Operating Parameters ................................................. 74

4.26 Performance Monitoring Strobe Light ................................................. 75

4.27 Rewinding the Hoses .......................................................................... 76

4.28 Shutting Down and Packing Up the Machine ..................................... 78

4.29 Emergency Stop Procedure ................................................................ 79

4.30 Resetting a Low HTF Fault ................................................................. 80

4.31 Changing Fuel Sources ...................................................................... 83

4.32 Quick-Connect Coupling Usage and Care .......................................... 84

4.33 Operating States of the Beckett Burner Controller ............................. 85

4.34 Burner Controller Periods and Fault Conditions (Gas) ....................... 89

4.35 Operating at High Elevations .............................................................. 91

5 Accessories 92

5.1 Available Accessories ......................................................................... 92

5.2 Using the Remote Manifolds ............................................................... 93

5.3 Expanding the Machine’s Capacity ..................................................... 94

5.4 Diagram: Thawing 10,000 ft

2

............................................................. 95

5.5 Diagram: Curing 20,000 ft

2

Using Two HHS 2502 ............................. 96

5.6 Diagram: Curing 30,000 ft

2

Using Four HHS 2502 ............................. 97

5.7 Using Heat Exchangers to Heat Air .................................................... 98

5.8 Placement Limitations for the Heat Exchangers ................................. 99

5.9 Diagram: HX 50 Air Heating ............................................................. 100

5.10 Diagram: HX 100 Air Heating ........................................................... 101

5.11 Diagram: HX 200 Air Heating ........................................................... 102

5.12 Diagram: One Loop Thawing and HX 50 Air Heating ....................... 103

5.13 Diagram: One Loop Thawing and HX 100 Air Heating ..................... 104

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5.14 Diagram: One Loop Thawing and HX 200 Air Heating ..................... 105

5.15 Diagram: Two Loop Thawing and HX 50 Air Heating ....................... 106

5.16 Diagram: Two Loop Thawing and HX 100 Air Heating ..................... 107

5.17 Diagram: Two Loop Thawing and HX 200 Air Heating ..................... 108

5.18 Diagram: Three Loop Thawing and HX 50 Air Heating .................... 109

5.19 Diagram: Three Loop Thawing and HX 100 Air Heating .................. 110

5.20 Diagram: Three Loop Thawing and HX 200 Air Heating .................. 111

5.21 Diagram: Three Loop Curing and HX 50 Air Heating ....................... 112

5.22 Diagram: Three Loop Curing and HX 100 Air Heating ..................... 113

5.23 Diagram: Three Loop Curing and HX 200 Air Heating ..................... 114

5.24 Diagram: Six Loop Curing and HX 50 Air Heating ........................... 115

5.25 Diagram: Six Loop Curing and HX 100 Air Heating ......................... 116

5.26 Diagram: Six Loop Curing and HX 200 Air Heating ......................... 117

5.27 Diagram: Nine Loop Curing and HX 50 Air Heating ......................... 118

5.28 Diagram: Nine Loop Curing and HX 100 Air Heating ....................... 119

5.29 Diagram: Nine Loop Curing and HX 200 Air Heating ....................... 120

6 Burner Setup—Oil 121

6.1 Factory Settings ............................................................................... 121

6.2 Setting up the Burner ....................................................................... 121

6.3 Setting/Checking the Electrodes ...................................................... 124

6.4 Replacing the Burner Nozzle ............................................................ 126

6.5 Setting the “Z” Distance and Head Position ..................................... 128

6.6 Adjusting the Air Settings ................................................................. 130

6.7 Adjusting the Fuel Pressure—Oil Burner ......................................... 131

7 Burner Setup—Gas 132

7.1 Factory Settings ............................................................................... 132

7.2 Setting up the Burner ....................................................................... 132

7.3 Adjusting the Fuel Pressure ............................................................. 134

8 Maintenance 137

8.1 Periodic Maintenance Schedule ....................................................... 137

8.2 General Cleaning Guidelines ........................................................... 138

8.3 Changing a Turbulator/Cleaning a Turbulator Tube ......................... 139

8.4 Inspecting/Replacing the Rope Gasket ............................................ 140

8.5 Draining the Hydronic Heater and HTF Reservoir ............................ 141

8.6 Filling the HTF Reservoir .................................................................. 142

8.7 Filling a New Hose ........................................................................... 144

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8.8 Inspecting Fluid Systems .................................................................. 146

8.9 Replacing the Fuel Filter ................................................................... 147

8.10 Cleaning the HTF Strainer ................................................................ 148

8.11 Repairing a Hose .............................................................................. 150

8.12 Lubricating the Hose Reel System ................................................... 152

8.13 Inspecting the Electrical Components .............................................. 153

8.14 Removing the Oil Burner .................................................................. 155

8.15 Installing the Oil Burner .................................................................... 156

8.16 Removing the NG/LP Burner ............................................................ 157

8.17 Preparing the Machine for Installation of the NG/LP Burner ............. 159

8.18 Installing the NG/LP Burner .............................................................. 160

8.19 Connecting and Maintaining the Battery ........................................... 162

8.20 Storing the Machine .......................................................................... 163

8.21 Storing the Genset ............................................................................ 164

8.22 Preparing the Machine for Seasonal Operation ................................ 165

9 Genset Maintenance 166

9.1 Periodic Maintenance Schedule ....................................................... 166

9.2 Checking the Engine Oil ................................................................... 167

9.3 Changing the Engine Oil and Oil Filter ............................................. 168

9.4 Checking the Engine Coolant Level .................................................. 170

9.5 Replacing the Air Filter Element ....................................................... 171

9.6 Replacing Engine Fuel Filter ............................................................. 173

9.7 Changing Engine Coolant ................................................................. 175

9.8 Genset Shut-Down Codes ................................................................ 177

10 Troubleshooting 181

10.1 Troubleshooting Machine Performance ............................................ 181

10.2 Troubleshooting Oil Burners ............................................................. 183

10.3 Troubleshooting Gas Burners ........................................................... 184

10.4 Fault Codes of the Honeywell Burner Controller .............................. 185

11 Technical Data 191

11.1 E 5000 .............................................................................................. 191

11.2 Genset .............................................................................................. 192

11.3 Trailer ................................................................................................ 193

11.4 Dimensions ....................................................................................... 194

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MSDS: Dowfrost HD 50 195

Fuji Temperature Controller 202

Tire Safety Information 206

12 Schematics 218

12.1 E 5000 Schematic (Oil Burners) ....................................................... 218

12.2 E 5000 Schematic (Gas Burners) ..................................................... 220

12.3 E 5000 Schematic Components ....................................................... 222

12.4 Trailer Wiring Diagrams .................................................................... 226

12.5 Genset Schematic ............................................................................ 228

12.6 Gas Train Schematic ........................................................................ 229

12.7 Gas Train — Components ................................................................ 229

12.8 Wiring Diagram — Gas Burner Controller ........................................ 230

Table of Contents

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E 5000 Safety Information

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

messages 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.

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Safety Information E 5000

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

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E 5000 Safety Information

 Fire hazards from improper refueling techniques

 Fuel and its fumes

 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.

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Safety Information E 5000

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:

 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.

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E 5000 Safety Information

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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Safety Information E 5000

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 operating the machine.

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 to 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.

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E 5000 Safety Information

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).

1.5 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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Safety Information E 5000

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.

Generator 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.

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Wacker Neuson E5000 User manual

Wacker Neuson E5000 User manual

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