Wacker Neuson E5000 User manual

Type
User manual
5000193536 02 0411
5000193536
Operator’s Manual
Hydronic Surface Heater
E 5000
Copyright notice
© Copyright 2011 by Wacker Neuson Production Americas LLC
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
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.
Manufacturers
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.
wc_bo5000193536_02TOC.fm 5
Table of ContentsE 5000
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 Safety Guidelines for Operating Generators ...................................... 13
1.5 Safety Guidelines While Using Combustion Burners ......................... 14
1.6 Operator Safety while Using Internal Combustion Engines ............... 15
1.7 Towing Safety ..................................................................................... 16
1.8 Safety Guidelines for Maintaining the Machine .................................. 17
2 Labels 19
2.1 Label Locations .................................................................................. 19
2.2 Label Meanings .................................................................................. 20
3 Lifting and Transporting 26
3.1 Lifting the Machine ............................................................................. 26
3.2 Transporting the Machine ................................................................... 28
3.3 Hazardous Materials Placards ........................................................... 28
3.4 Transporting the Machine on a Flat Bed ............................................ 29
3.5 Towing the Machine ........................................................................... 31
3.6 Trailer Wiring Diagrams ...................................................................... 32
4 Operation 34
4.1 System Description ............................................................................ 34
4.2 External Components ......................................................................... 35
4.3 Internal Components .......................................................................... 36
4.4 Rear Components .............................................................................. 37
4.5 Pumps, Gauges, and Valves .............................................................. 38
4.6 Control Panel Detail ........................................................................... 39
4.7 Control Panel Components ................................................................ 40
4.8 General Sequence of Operation ......................................................... 41
4.9 Recommended Fuels ......................................................................... 42
4.10 Pre-Season Start-up Preparation ....................................................... 42
4.11 Checking the Fuel Level ..................................................................... 43
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Table of Contents E 5000
4.12 Checking the HTF Level ......................................................................44
4.13 Positioning the Machine ......................................................................45
4.14 Connecting Power to the Machine ......................................................46
4.15 Pre-Starting Checks ............................................................................47
4.16 Applying Power to the Machine ...........................................................49
4.17 Preheating the HTF .............................................................................50
4.18 Setting the Operating Temperature .....................................................51
4.19 Initiating the HTF Flow ........................................................................51
4.20 Unwinding and Positioning the Hoses .................................................53
4.21 Using the Remote Manifolds ...............................................................55
4.22 Monitoring the Operating Parameters .................................................56
4.23 Performance Monitoring Strobe Light ..................................................56
4.24 Stopping the Machine Temporarily ......................................................57
4.25 Shutting Down and Packing Up the Machine ......................................58
4.26 Emergency Shutdown Procedure ........................................................59
4.27 Rewinding the Hoses ..........................................................................60
4.28 Resetting a Low HTF Fault ..................................................................62
4.29 Changing Fuel Sources .......................................................................66
4.30 Quick-Connect Coupling Usage and Care ..........................................67
4.31 Burner Controller Periods and Modes (Oil) .........................................68
4.32 Burner Controller Periods and Fault Conditions (Gas) ........................72
4.33 Operating at High Elevations ...............................................................73
5 Accessories 75
5.1 Available Accessories .........................................................................75
5.2 Expanding the Surface Heating Capacity ............................................76
5.3 Using Heat Exchangers (to Heat Air) ..................................................77
5.4 HX 50 Connection Diagram .................................................................78
5.5 HX 100 Connection Diagram ...............................................................79
5.6 HX 200 Connection Diagram ...............................................................80
6 Burner Setup 81
6.1 Factory Settings ..................................................................................81
6.2 Setting up the Burner ..........................................................................81
6.3 Setting/Checking the Electrodes .........................................................84
6.4 Replacing the Oil Burner Nozzle .........................................................86
6.5 Setting the “Z” Distance .......................................................................89
6.6 Adjusting the Air Settings ....................................................................91
6.7 Adjusting the Fuel Pressure ................................................................92
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Table of ContentsE 5000
7 Maintenance 94
7.1 Periodic Maintenance Schedule ......................................................... 94
7.2 General Cleaning Guidelines ............................................................. 95
7.3 Installing the NG/LP Burner ................................................................ 96
7.4 Changing the Genset Oil and Filter .................................................... 98
7.5 Changing a Turbulator/Cleaning a Turbulator Tube ........................... 99
7.6 Inspecting/Replacing the Rope Gasket ............................................ 100
7.7 Draining the Hydronic Heater and HTF Reservoir ............................ 101
7.8 Filling the HTF Reservoir .................................................................. 102
7.9 Filling a New Hose ........................................................................... 104
7.10 Inspecting Fluid Systems ................................................................. 106
7.11 Replacing the Fuel Filter .................................................................. 107
7.12 Repairing a Hose .............................................................................. 108
7.13 Lubricating the Hose Reel System ................................................... 110
7.14 Inspecting the Electrical Components .............................................. 111
7.15 Removing the Burner ....................................................................... 113
7.16 Installing the Burner ......................................................................... 114
7.17 Storing the Machine ......................................................................... 115
7.18 Preparing the Machine for Seasonal Operation ............................... 116
8 Basic Troubleshooting 117
8.1 Troubleshooting the Machine ........................................................... 117
9 Technical Data 119
9.1 E 5000 .............................................................................................. 119
9.2 Dimensions ....................................................................................... 120
10 Schematics 121
10.1 E 5000 Schematic (Oil) .................................................................... 121
10.2 E 5000 Schematic (Gas) .................................................................. 123
10.3 E 5000 Schematic Components ....................................................... 125
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Table of Contents E 5000
E 5000 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 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 mes-
sages 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 mes-
sages that follow this signal word.
Safety Information E 5000
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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 HTF or radiant heat from the hoses
E 5000 Safety Information
ghi_si000466gb.fm 11
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.
1.3 Safety Guidelines for Operating the Machine
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
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
Machine
condition
Only operate the machine when:
The Heat Exchanger is in proper working order.
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.
Safety Information E 5000
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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.
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.
E 5000 Safety Information
ghi_si000466gb.fm 13
1.4 Safety Guidelines for Operating Generators
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.
Before
operating the
machine
Always follow starting and stopping instructions described in this manual. Know
how to operate and stop the generator before starting it.
Do not operate the generator when open containers of fuel, paint, or other
flammable liquids are near.
Do not allow untrained personnel to operate or service the generator. The
generator set should be set up and repaired only by a certified electrician.
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.
While the
machine is
operating
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.
Do not operate the generator, or tools attached to the generator, with wet
hands.
Do not touch the hot engine, exhaust, or generator components. Burns will
result.
Do not remove the radiator cap when the engine is running or hot. The radiator
fluid is hot and under pressure and may cause severe burns!
Maintenance
guidelines
Only a trained electrician, familiar with this equipment, should attempt repairs to
the generator! Test procedures which require that the generator be running
must be performed using extreme caution.
Remove all jewelry, 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 machine.
Engine antifreeze is toxic to humans and animals. Clean up spills and dispose
of used engine antifreeze in accordance with local environmental regulations.
DO NOT pressure wash the control panel, generator end, or any other electrical
components when cleaning the machine. Never allow water to accumulate
around the base of the generator set. If water is present, DO NOT service!
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 all safety information contained in this Operator’s Manual and the genset
owner’s manual before operating or servicing this equipment.
Safety Information E 5000
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1.5 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:
When refueling 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.
Do not use gasoline, crankcase oil, or any oil containing gasoline.
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.
E 5000 Safety Information
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1.6 Operator Safety while Using Internal Combustion Engines
Operating
safety
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 sparks or 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 start the engine if fuel has spilled or a fuel odor is present. Move the
machine away from the spill and wipe the machine dry before starting.
Refueling
safety
When refueling the engine:
Clean up any spilled fuel immediately.
Refill the fuel tank in a well-ventilated area.
Replace the fuel tank cap after refueling.
Do not smoke.
Do not refuel a hot or running engine.
Do not refuel the engine near sparks or open flames.
Do not refuel if the machine is positioned in a truck fitted with a plastic bed liner.
Static electricity can ignite the fuel or fuel vapors.
Engine
starting
Do not use combustible fluids to help start the generator engine. Combustible
fluids may cause permanent damage.
WARNING
Internal combustion engines present special hazards during operation and fueling.
Failure to follow the warnings and safety standards could result in severe injury or
death.
f Read and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
Exhaust gas from the engine contains carbon monoxide, a deadly poison.
Exposure to carbon monoxide can kill you in minutes.
f NEVER operate the machine indoors or in an enclosed area unless the
machine is vented properly.
Safety Information E 5000
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1.7 Towing Safety
Check
equipment
condition
Perform the following equipment checks before connecting the machine to the
towing vehicle.
Verify that the trailer and the towing vehicle are in serviceable condition.
Verify that the hitch and coupling on the vehicle are rated equal to, or greater
than, the trailer's “gross vehicle weight rating” (GVWR).
Inspect the hitch and coupling for wear or damage. DO NOT tow the trailer
using defective parts.
Check the tires on the trailer for tread wear, inflation, and condition. Replace
worn tires.
Check that the lug nuts holding the wheels are tight and that none are missing.
Before towing
Perform the following checks before towing the machine.
Make sure the coupling is securely fastened to the vehicle.
Connect the safety chains.
Connect the breakaway cable safety hook to the bumper or rear of the vehicle.
DO NOT attach it to the hitch.
Test the surge brakes on the trailer and the brakes on the vehicle that will be
used for towing.
Make sure directional and trailer lights are connected and working properly.
WARNING
Improper towing techinique can cause traffic accidents and equipment damage.
f Read and follow the safety guidelines below before towing this machine.
E 5000 Safety Information
ghi_si000466gb.fm 17
1.8 Safety Guidelines for Maintaining the Machine
Training
Only trained personnel should troubleshoot or repair electrical problems
occurring with the machine.
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).
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.
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.
Replace all missing and hard-to-read labels.
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.
Safety Information E 5000
18 ghi_si000466gb.fm
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 5000 Labels
ghi_si000467gb.fm 19
2 Labels
2.1 Label Locations
wc_gr007479
1
32
30
5
31
14
3
6
3
13
13
13
2
2313 33 28
9
8
18
4
5
29
24
27
31
1112 17
23
Labels E 5000
20 ghi_si000467gb.fm
2.2 Label Meanings
1
Warning: Electrical shock hazard!
Refer to the Operator’s Manual.
2
HTF MSDS label.
This label is the Material Safety Data Sheet for the
HTF installed in the factory.
3
Warning: Hot surface hazard.
Wear safety gloves.
Wear eye protection.
4
Warning:
Read and understand the supplied Operator’s Man-
ual before operating this machine. Failure to do so
increases the risk of injury to yourself and others.
WARNING
WARNUNG
ADVERTENCIA
AVERTISSEMENT
173199
READ AND UNDERSTAND THE SUPPLIED OPERATOR’S MANU
AL BEFORE
OPERATING THIS MACHINE. FAILURE TO DO SO INCREASES THE
RISK OF INJURY TO YOURSELF OR OTHERS.
VOR INBETRIEBNAHME DIESES GREÄTES BEIGEFÜGTE BETRIEBSVOR-
SCHRIFT LESEN UND VERSTEHEN. NICHTBEFOLGUNG ERHÖHT DAS
RISIKO ZU EIGENER VERLETZUNG ODER ANDERER.
LEA Y ENTIENDA EL MANUAL DE OPERACION PROVISTO CON EL
EQUIPO ANTES DE QUE OPERE ESTE EQUIPO. DE NO HACERSE
ASI. PODRIA AUMENTAR EL RIESGO DE DAÑOS PERSONALES Y
A OTRAS PERSONAS.
LIRE ET COMPRENDRE LA NOTICE D’EMPLOI FOURNIE AVEC LA
MACHINE AVANT DE LA METTRE EN SERVICE. A DEFAUT. VOUS
AUGMENTERIEZ LE RISQUE DE VOUS EXPOSER ET LES AUTRES
A DES BLESSURES.
173221
WARNING
WARNUNG
ADVERTENCIA
AVERTISSEMENT
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Wacker Neuson E5000 User manual

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