Wacker Neuson E3000 User manual

Type
User manual
Operator’s Manual
Hydronic Surface Heater
E 3000
0178603en 002 0110
0178603EN
Copyright
notice
© Copyright 2010 by Wacker Neuson Corporation.
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the machine. Any
other type of reproduction is prohibited without express written permission from
Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker Neuson Corporation
represents an infringement of valid copyrights. Violators will be prosecuted.
Trademarks
All trademarks referenced in this manual are the property of their respective owners.
Manufacturer
Wacker Neuson Corporation
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
www.wackerneuson.com
Original
instructions
This Operator’s Manual presents the original instructions. The original language of this
Operator’s Manual is American English.
Foreword
ghi_tx001159gb.fm 3
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.
Refer to the separate Repair Manual for detailed instructions on servicing and
repairing the machine.
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.
Copyright 2009 by Wacker Neuson Corporation.
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.
CALIFORNIA
Proposition
65 Warning:
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.
Machine Item Number Revisions Covered
E 3000 0620158 200 and higher
E 3000G 0620219 200 and higher
E 3000 LB 0620678 all
E 3000 LB-G 0620679 all
Foreword
ghi_tx001159gb.fm 4
Laws
pertaining to
spark
arresters
NOTICE: State Health Safety Codes and Public Resources Codes specify that in
certain locations spark arresters be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed to prevent accidental
discharge of sparks or flames from the engine exhaust. Spark arresters are
qualified and rated by the United States Forest Service for this purpose. In order to
comply with local laws regarding spark arresters, consult the engine distributor or
the local Health and Safety Administrator.
NOTICE:
Trademarks
All trademarks referenced in this manual are the property of their respective
owners.
E 3000 Table of Contents
5
1 Safety Information 9
1.1 Signal Words Found in this Manual ...................................................... 9
1.2 Safety Guidelines for Operating the Machine ..................................... 10
1.3 Safety Guidelines for Lifting the Machine ........................................... 11
1.4 Safety Guidelines While Using Combustion Burners ......................... 12
1.5 Safety Guidelines while Using Internal Combustion Engines ............. 12
1.6 Safety Guidelines for Maintaining the Machine .................................. 13
2 Labels 14
2.1 Label Locations .................................................................................. 14
2.2 Warning Labels .................................................................................. 15
2.3 Informational Labels ........................................................................... 17
2.4 Procedural Labels .............................................................................. 19
3 Lifting and Transporting 20
3.1 Lifting the Machine ............................................................................. 20
3.2 Hazardous Materials Placards ........................................................... 21
3.3 Transporting the Machine on a Flat Bed ............................................ 22
3.4 Towing the Machine ........................................................................... 24
3.5 Trailer Wiring Diagrams ...................................................................... 25
4 Operation 27
4.1 Intended Purpose and System Description ........................................ 27
4.2 External Components ......................................................................... 28
4.3 Internal Components .......................................................................... 29
4.4 Rear Components .............................................................................. 30
4.5 Pumps, Gauges, and Valves .............................................................. 31
4.6 Control Panel Detail ........................................................................... 32
4.7 Control Panel Components ................................................................ 33
4.8 General Sequence of Operation ......................................................... 34
4.9 Recommended Fuels ......................................................................... 35
4.10 Checking the HTF Level ..................................................................... 36
4.11 Positioning the Machine ..................................................................... 37
4.12 Connecting Power to the Machine ..................................................... 38
Table of Contents E 3000
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4.13 Pre-Starting Checks ............................................................................40
4.14 Applying Power to the Machine ...........................................................42
4.15 Preheating the HTF .............................................................................43
4.16 Initiating the HTF Flow ........................................................................44
4.17 Unwinding and Positioning the Hoses .................................................46
4.18 Monitoring the Operating Parameters .................................................47
4.19 Stopping the Machine Temporarily ......................................................48
4.20 Shutting Down the Machine ................................................................49
4.21 Rewinding the Hoses ..........................................................................50
4.22 Resetting a Low HTF Fault ..................................................................52
4.23 Quick-Connect Coupling Usage and Care ..........................................55
4.24 Burner Controller Periods and Modes .................................................56
4.25 Operating at High Elevations ...............................................................60
5 Accessories 61
5.1 Available Accessories .........................................................................61
5.2 Expanding the Surface Heating Capacity ............................................62
5.3 Surface Heat Expansion Detail—Option 1 ..........................................63
5.4 Surface Heat Expansion Detail—Option 2 ..........................................64
5.5 Mounting and Connecting the Auxiliary Pump Panel ..........................66
5.6 Using Heat Exchangers (to Heat Air) ..................................................68
5.7 HX 200 Connection Diagram ...............................................................69
5.8 HX 100 Connection Diagram ...............................................................70
5.9 HX 50 Connection Diagram .................................................................72
6 Burner Setup 75
6.1 Factory Settings ..................................................................................75
6.2 Setting up the Burner ..........................................................................75
6.3 Setting/Checking the Electrodes .........................................................78
6.4 Replacing the Burner Nozzle ...............................................................80
6.5 Setting the “Z” Distance .......................................................................83
6.6 Adjusting the Air Settings ....................................................................85
6.7 Adjusting the Fuel Pressure ................................................................86
7 Maintenance 87
E 3000 Table of Contents
7
7.1 Periodic Maintenance Schedule ......................................................... 87
7.2 General Cleaning Guidelines ............................................................. 88
7.3 Changing a Turbulator/Cleaning a Turbulator Tube ........................... 89
7.4 Inspecting/Replacing the Rope Gasket .............................................. 90
7.5 Draining the Hydronic Heater and HTF Reservoir .............................. 91
7.6 Filling the HTF Reservoir .................................................................... 92
7.7 Filling a New Hose ............................................................................. 94
7.8 Inspecting Fluid Systems ................................................................... 96
7.9 Replacing the Fuel Filter .................................................................... 97
7.10 Repairing a Hose ................................................................................ 98
7.11 Inspecting the Electrical Components .............................................. 100
7.12 Removing the Burner ....................................................................... 102
7.13 Installing the Burner ......................................................................... 103
7.14 Cleaning the HTF Strainer Basket .................................................... 104
7.15 Storing the Machine ......................................................................... 105
7.16 Preparing the Machine for Seasonal Operation ............................... 106
8 Schematics 107
8.1 E 3000 Composite Schematic .......................................................... 107
8.2 E 3000 Composite Components (SN 1122 and higher) ................... 108
8.3 Heating System Circuit ..................................................................... 112
8.4 Circulation System Circuit ................................................................ 113
8.5 Rewind System Circuit ..................................................................... 114
8.6 Onan Genset Schematic ................................................................. 115
9 Basic Troubleshooting 117
9.1 Troublshooting the Machine ............................................................. 117
10 Technical Data 119
10.1 E 3000 .............................................................................................. 119
10.2 Dimensions ....................................................................................... 120
Table of Contents E 3000
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E 3000 Safety Information
ghi_si000336gb.fm 9
1 Safety Information
1.1 Signal Words Found in this Manual
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.
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 indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
f Obey all safety messages that follow this symbol to avoid injury or death.
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
f Obey all safety messages that follow this symbol to avoid possible injury or
death.
CAUTION indicates a situation which, if not avoided, could result in minor or mod-
erate injury.
f Obey all safety messages that follow this symbol to avoid possible minor or
moderate injury.
E 3000 Safety Information
ghi_si000336gb.fm 10
1.2 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 Corporation 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.
Machine
condition
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.
When operating the machine:
Do not modify or defeat the safety devices.
Do not use worn electrical cords.
Do not use faulty fuel supplies.
Guidelines for
operator
When operating the machine:
Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
Wear protective clothing appropriate to the job site when operating the
machine.
Wear safety glasses.
Wear gloves when handling the heat transfer hoses.
When operating the machine:
Do not operate a machine in need of repair.
Do not smoke near the machine.
Do not disconnect the heat transfer hoses when the pumps are operating or a
burner is firing.
Work space
When operating the machine:
Position the machine on a firm, noncombustible, level surface, and chock the
wheels.
Position the machine on the job site so that neither it nor the operator are
standing in water.
E 3000 Safety Information
ghi_si000336gb.fm 11
Keep the area immediately surrounding and underneath the machine clean,
neat, and free of debris and combustible materials.
Keep the area above the machine clear of debris that could fall on the machine.
Store the machine properly when it is not being used.
Keep unauthorized personnel, children, and pets away from the machine.
When operating the machine:
Never operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
1.3 Safety Guidelines for Lifting the Machine
Lifting/
transporting
the machine
When lifting/transporting the machine:
Make sure all lifting devices are attached securely and have enough weight-
bearing capacity to lift or hold the machine safely.
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.
Only use suitable transport vehicles with sufficient load-carrying capacity.
When lifting the machine:
Never walk or stand under a suspended machine.
Never climb, sit, or stand on the machine while it is being lifted or transported.
Do not operate the machine when it is being lifted or towed.
E 3000 Safety Information
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1.4 Safety Guidelines While Using Combustion Burners
When using the machine:
Clean up any spilled fuel immediately.
Replace the fuel tank cap after refueling the machine.
Refill the fuel tank in a well-ventilated area.
Shut down the generator, if equipped, when refueling.
When using the machine:
Do not fill or drain the fuel tank near an open flame or while the machine is
running.
Do not smoke when refueling the machine.
1.5 Safety Guidelines while Using Internal Combustion Engines
Running the
engine
When running the engine:
Keep the area around exhaust pipe free of flammable materials.
Check the fuel lines and the fuel tank for leaks and cracks before starting the
engine. Do not run the machine if fuel leaks are present or the fuel lines are
loose.
When running the engine:
Do not smoke while operating the machine.
Do not run the engine near open flames.
Do not touch the engine or muffler while the engine is running or immediately
after it has been turned off.
Do not operate a machine when its fuel cap is loose or missing.
Do not use combustible fluids to help start the generator engine. Combustible
fluids may cause permanent damage.
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.
DANGER
Exhaust gas from the engine contains carbon monoxide, a deadly poison. Expo-
sure 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.
E 3000 Safety Information
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1.6 Safety Guidelines for Maintaining the Machine
Training
Only trained personnel should troubleshoot or repair electrical problems
occurring with the machine.
Cleaning
When cleaning and servicing the machine:
Keep the area around the burner free of debris such as leaves, paper, cartons,
etc.
Keep the machine clean and labels legible.
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 parts.
Fumes from fuels and solvents can become explosive!
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.
Re-install the safety devices and guards after repairs and maintenance.
Keep all electrical cords away from heat, oil, vibrating surfaces, and sharp
edges.
Replacing
parts and
labels
When maintaining the machine:
Replace worn or damaged components.
Use only spare parts recommended by Wacker Neuson Corporation.
Replace all missing and hard-to-read labels.
Replace or repair electrical components with components that are identical in
rating and performance as the original component.
When maintaining the machine:
Do not attempt tire repairs.
Accessories,
safety devices
and
modifications
When using the machine:
Use only accessories/attachments that are recommended by Wacker Neuson
Corporation.
When using the machine:
Never operate the machine if any safety devices or guards are missing or
inoperative.
Do not defeat safety devices.
Do not modify the machine without the express written approval of Wacker
Neuson Corporation.
E 3000 Labels
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2 Labels
2.1 Label Locations
E 3000 Labels
ghi_si000470gb.fm 15
2.2 Warning Labels
Ref. Label Definition
1
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.
2CAUTION
This machine uses diesel fuel.
3 WARNING!
Do not engage trailer jack while transporting
the machine.
Refer to the Operator’s Manual for further
instructions.
D
DIESEL
CAUTION
VORSICHT
PRECAUCION
PRECAUCION
WARNING
WARNUNG
ADVERTENCIA
AVERTISSEMENT
173200
E 3000 Labels
ghi_si000470gb.fm 16
4CAUTION!
Hot surface hazard!
5 WARNING!
Hot surface hazard.
Wear safety gloves.
Wear eye protection.
6 WARNING!
Hand entanglement hazard. Moving parts
can crush and cut. Do not operate with guard
removed.
7 WARNING!
Electrical shock hazard!
Refer to the Operator’s Manual.
8 NOTICE!
Lift point.
Attach lifting device in this location.
Ref. Label Definition
WARNING
WARNUNG
ADVERTENCIA
AVERTISSEMENT
173199
WARNING
WARNUNG
ADVERTENCIA
AVERTISSEMENT
173224
CAUTION
VORSICHT
PRECAUCION
PRECAUTION
E 3000 Labels
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2.3 Informational Labels
Ref. Label Definition
9 Tie-down location marker.
10 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.
11 Machine rating label: This label indicates rat-
ing information for the machine.
12 Weight/mass label: This label indicates the
total weight of the machine, including the
trailer and a full fuel tank.
8582
3900
E 3000 Labels
ghi_si000470gb.fm 18
13 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.
17 Not a step.
HTF MSDS label.
This label is the Material Safety Data Sheet
for the HTF installed in the factory.
Ref. Label Definition
E 3000 Labels
ghi_si000470gb.fm 19
2.4 Procedural Labels
14 Do not reset.
Refer to Operator’s Manual.
15 Hose reel brake label. This label indicates
information regarding the operation of the
hose reel brake assembly.
16 Fuel blend guide: This label indicates the
proper fuel blending requirements based
upon power source and ambient temperature
ranges. Consult the Operator’s Manual for
more information.
Magnetic placards that display the numeric
hazardous material code for diesel fuel are
included with each machine. These placards
must be placed on three sides of the
machine during transport if the fuel tank con-
tains any amount of fuel or fuel residue.
173201
1202
3
E 3000 Lifting and Transporting
ghi_tx001160gb.fm 20
3 Lifting and Transporting
3.1 Lifting the Machine
Prerequisites
Properly rated lifting equipment (crane or hoist). See Chapter Technical Data.
Machine stopped. See topic Stopping the Machine.
All doors and access covers closed and secured.
Procedure
Follow the procedure below to lift the machine.
1. Attach the lifting equipment to one of the lifting eyes (a) on the machine using
hooks, shackles, and chains.
2. Lift the machine a small distance.
3. Check for stability. If necessary, lower the machine, reposition the lifting device,
and lift the machine a small distance again.
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.
WARNING
Crushing hazard. An unstable machine may cause the lifting devices to fail. You
may be crushed if the lifting devices fail.
f Check for stability before continuing.
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Wacker Neuson E3000 User manual

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User manual

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