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Tamarack Industries Thawzall XHR700, Operator'S Manual

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Tamarack Industries Thawzall XHR700 Operator'S Manual Download Page 6

Table of contents

Title

Pages

Ways to contact Us 

1

Unit Information 

2

Proposition 65 warning

3

Introduction

4

Safety

6-11

Warranty

12-13

How it works

14

Controls

15

Operating Procedures

16

Main Screen Overview

17-22

Diagnostics Overview

23-26

Service screen overview

27

Troubleshooting

28-32

Maintenance

33-44

Specifications

45

MSDS

46-49

Schematics

50-54

5

Summary of Contents for Thawzall XHR700

Page 1: ...Operators Manual XHR700 Part 600280 Date Sept 2019 CATERPILLAR DEUTZ ENGINES ...

Page 2: ...egular hours are directed to the On call technician Af ter hours support is reserved for issues that cannot wait until the next business day for resolution If no answer please leave a message and we will get back to you as soon as possible By Email info thawzall com Feel free to email us at any time with technical questions or parts inquiries Please include the year make and model of your unit if ...

Page 3: ...______ ______ _______ Machine model ____XHR700____________________ Machine serial number ________________ Vin number located on trailer tongue Manufactured by Thawzall LLC A DIVISION OF TAMARACK INDUSTRIES 2736 Latoka Lane Unit B Alexandria MN 56308 Phone 320 759 1588 Fax 320 759 1583 Tech Support 888 757 3545 Website www Thawzall com E Mail support tamarack ind com 2 ...

Page 4: ...ctive harm Some examples of these chemicals are Lead from lead based paints Crystalline silica from bricks Cement and other masonry products Arsenic and chromium from chemically treated lumber Your risk from these exposures varies depending on how often you do this type of work To reduce your exposure to these chemicals ALWAYS work in a well ventilated area and work with approved safety equipment ...

Page 5: ...trouble free operation of your XHR700 requires that you and anyone else who will be operat ing or maintaining the Heater read and understand the Safety Operation Maintenance and Trouble Shooting information contained in the Operator s Manual This manual is applicable to the XHR700 built by Tamarack Industries Use the Table of Contents as a guide when searching for specific information Keep this ma...

Page 6: ...ion 65 warning 3 Introduction 4 Safety 6 11 Warranty 12 13 How it works 14 Controls 15 Operating Procedures 16 Main Screen Overview 17 22 Diagnostics Overview 23 26 Service screen overview 27 Troubleshooting 28 32 Maintenance 33 44 Specifications 45 MSDS 46 49 Schematics 50 54 5 ...

Page 7: ...ces Indicates a potentially hazardous situa tion that if not avoided may result in minor or moderate injury It may also be used to alert against unsafe prac tices SIGNAL WORDS Note the use of the signal words DANGER The Safety Alert symbol identifies important safety messages on the Tamarack Heat King and in the manual When you see this symbol be alert to the possibility of personal injury or deat...

Page 8: ...in the manual and to follow these Most accidents can be avoided A person who has not read and understood all operating and safety instructions is not qualified to operate the machine An untrained operator exposes himself and bystanders to possible serious injury or death Do not modify the equipment in any way Unauthorized modification may impair the function and or safety and could affect the life...

Page 9: ...cinity of open flames sparks or while smoking 14 Explosion Hazard Battery Take care when handling battery if installed TIRE SAFETY 1 Failure to follow proper procedures when mounting a tire on a wheel or rim can produce an explosion which may result in serious injury or death 2 Do not attempt to mount a tire unless you have the proper equipment and experience to do the job 3 Have a qualified tire ...

Page 10: ...ng or adjusting the Heater 2 Place all controls in their OFF position disconnect power cords and wait for all moving parts to stop before servicing adjusting or maintaining 3 Do not allow riders in or on machine during transport 4 Clear the area of bystanders especially small children before starting and operating 5 Keep the working area clean and free of de bris to prevent slipping or tripping Cl...

Page 11: ...xceed 55 mph under ideal conditions Reduce speed under adverse weather road or terrain conditions Avoid sudden lane changes U turns etc Sudden maneuvers may cause tipping rollover jackknifing or sliding of the trailer and without warning loss of control of the towing vehicle may result Allow for increased braking distance due to weight of trailer Read the Operator s Manual before towing 4 Cross th...

Page 12: ...rate this equipment until such information has been reviewed Annually review this information before the season start up Make these periodic reviews of SAFETY and OPERATION a standard practice for all of your equipment We feel that an untrained operator is unqualified to operate this machine A sign off sheet is provided for your record keeping to show that all personnel who will be working with th...

Page 13: ...ctions WARRANTY REGISTRATION please print This form must be filled out by the dealer and signed by both the dealer and the customer at the time of deliv ery Customer s Name Distributor Name Address Address City State Code City State Code Phone Number Check One Contact Name Private THAWZALL Model Contractor Serial Number Other Delivery Date I have thoroughly instructed the buyer on the above descri...

Page 14: ...e in writing within ten days from receipt of merchandise 7 RETURN OF GOODS Written permission from Tamarack must be obtained before returning any mer chandise All transportation charges must be borne by the purchaser Credit for returned goods will be based on the original price paid less 20 Special parts or custom built items cannot be returned for credit 8 LIMITATION OF LIABILITY Tamarack s liabi...

Page 15: ...he XHR700 has a diesel engine and AC alternator which is used to provide power to the on board heater bank and blower motor External air is drawn into the enclosure this air is then heated by the residual heat from the internal components The air is further heated by being drawn through the coolant radiator and through a heat exchanger utilizing hot exhaust gases This heated air is finally blown a...

Page 16: ...raphics parameters 2 2 Touch activation as described in Screen Operation Section 3 HMI INDICATORS 3 1 Power Indication Mode Status 3 2 USB Connected 3 3 Network Connected 3 4 CPU Processing 4 DIAL ENCODER 4 1 Parameter Adjustment 5 HOME KEY 5 1 Returns To Previous Screen 6 ESCAPE KEY 6 1 Returns To Previous Screen 7 USB PORT 7 1 Software Update Factory Use ...

Page 17: ...y cycling heaters 2 thru 4 to achieve desired Heat Setting selected on Main Screen 3 1 LOW Setpoint Factory Default 120DegF 3 2 MED Setpoint Factory Default 182DegF 3 3 HIGH Setpoint Factory Default 222DegF NOTE The Heat Control also monitors the Engine Load Percentage which may cause the controller to lower the Heater load for an interval of time This is to optimize the performance of the equipme...

Page 18: ...d when the Ignition is OFF 1 2 Machine status is displayed here including Faults Warnings and Engine Codes 1 3 Fuel Level is displayed here Data is transmitter over J1939 from SKIM 1 4 Engine Hours is displayed here Data is transmitted over J1939 network from Engine 1 5 Engine Oil Level is displayed with the following icon Data is transmitted over J1939 network from SKIM Inactive Active ...

Page 19: ...r information Inactive Active 1 9 DPF Active is displayed with the following icon Data is transmitted over J1939 network from Engine Refer to engine manufacturer for further information Inactive Active 1 10 High Exhaust Temp is displayed with the following icon Data is transmitted over J1939 network from Engine Refer to engine manufacturer for further information Inactive Active 1 11 DPF Disabled ...

Page 20: ...CREEN 2 4 Press adjacent tactile button or touch screen icon to navigate to ENGINE SCREEN 3 FUNCTIONS 3 1 System Start is activated here This initiates the start sequence of the machine 3 2 System Stop is activated here This commands the shutdown sequence of the machine 3 3 Gate Open is activated here Function illuminates when active 3 3 1 NOTE Only displayed when Actuator is Active in OEM Setting...

Page 21: ...twork from Engine Refer to engine manufacturer for further information 1 3 Engine Oil Pressure is displayed in the field below this icon Data is transmitted over J1939 network from Engine Refer to engine manufacturer for further information 1 4 Fuel Level is displayed in the field below this icon Data is transmitter over J1939 from SKIM 2 NAVIGATION Notice navigation features carry over from Main ...

Page 22: ...minimum warm up temperature the Engine must reach before proceeding to High Idle startup 1 5 1 NOTE High Idle setting is 1800 RPM 1 6 DUCT OVER TEMP is the max allowable temperature within the Duct before the machine will perform a commanded shutdown sequence 1 7 LOW IDLE ENGINE TEMP is the minimum cool down temperature the Engine should reach before proceeding to Low Idle shutdown 1 7 1 NOTE If t...

Page 23: ...been granted to modify factory settings 2 NAVIGATION 2 1 Press adjacent tactile button or touch screen icon to navigate to OEM LOGIN SCREEN Factory Use ONLY 2 2 Press adjacent tactile button or touch screen icon to navigate to TIME DATE SCREEN 2 3 Press adjacent tactile button or touch screen icon to navigate to CALIBRATION SCREEN 2 4 Returns To Previous Screen 3 FUNCTIONS Settings Unlocked 3 1 To...

Page 24: ...n of Digital functions being controlled 1 2 INPUTS displays the status for a column of Digital Analog functions being monitored 1 3 STATUS displays the online or offline status of networked devices 2 NAVIGATION 2 1 Press adjacent tactile button or touch screen icon to navigate to INFORMATION SCREEN 2 2 Returns To Previous Screen 3 FUNCTIONS Active Standby Disconnected ...

Page 25: ...loaded to compatible USB storage device Factory Use 3 3 Parameters Import is activated here Machine parameters can be downloaded to compatible USB storage device Factory Use INFORMATION SCREEN OVERVIEW 1 DISPLAY 1 1 This screen displays the symbols used within the application with a description of each 1 1 1 NOTE The software version is located in the bottom right of screen ...

Page 26: ...ol relays provide ON OFF LED indication 1 2 1 1 3 DC Power Supply provides indication that output voltage is good 90 1 3 1 1 4 Class CC Fuse Holder provide Blown Fuse Status 1 4 1 1 5 LM1 provides indication of status of the following 1 5 1 Over voltage Relay Yellow 1 5 2 Power On Green 1 5 3 Under voltage Relay Yellow 1 5 4 ...

Page 27: ...vides indication of status 1 1 1 E STOP pressed LED ON 1 1 2 E STOP pulled out LED OFF 1 1 3 2 600318 Air Flow Sensor 2 1 Sensor provides indication of status 2 1 1 Power Standby Red 2 1 2 Relay Closed Green 3 Duct Temperature Sensor 3 1 Sensor provides indication of power when Green ...

Page 28: ...a PDF containing information pertaining to that subject 1 2 Returns To Previous Screen 2 FUNCTIONS 2 1 Engine Ignition can be toggled via screen press or adjacent button Icon also displays the status as follows Ignition ON Ignition OFF 500 Hour is a column tracking the engine hours between services for maintenance required after 500 hours 2 2 will reset the corresponding service performed 27 ...

Page 29: ... 2 HOW TO CLEAR Cycle Power 4 3 POSSIBLE ISSUES Duct is blocked Gate Actuator closed too far ambient temperature too high 5 CODE FAULT Duct Temp Sensor 5 1 CAUSE Duct Temp Sensor signal not detected 5 2 HOW TO CLEAR Correct signal 5 3 POSSIBLE ISSUES Check wiring or replace sensor 6 CODE FAULT Check Oil Level 6 1 CAUSE Oil Level Sensor input OFF indicating oil has dropped below safe level 6 2 HOW ...

Page 30: ...ect Cause Cycle Power 4 3 POSSIBLE ISSUES Genset or AVR malfunctioned Refer to Factory 5 CODE CYCLE POWER Overvoltage Shutdown 5 1 CAUSE 3 Phase AC power exceed upper tolerance 5 2 HOW TO CLEAR Correct Cause Cycle Power 5 3 POSSIBLE ISSUES Genset or AVR malfunctioned Refer to Factory MACHINE NOTIFICATIONS Codes that serve to notify operator Some may prevent machine start 1 CODE STARTUP CYCLE 1 1 C...

Page 31: ...librated 8 1 CAUSE Actuator Calibration procedure has not been performed 8 2 HOW TO CLEAR Perform Calibration Procedure 9 CODE FAULT Actuator Position Sensor 9 1 CAUSE Actuator Position Sensor signal not detected 9 2 HOW TO CLEAR Correct Cause 9 3 POSSIBLE ISSUES Check wiring or replace Actuator 10 CODE FAULT Actuator Stalled Detected 10 1 CAUSE No position change detected when operating Actuator ...

Page 32: ...ES 4 1 Disconnect OFF 4 1 1 Turn On 4 2 MMP1 Tripped 4 2 1 Inspection by qualified personnel required 4 3 AVR Failure 4 3 1 Refer to Factory 4 4 Genset Failure 4 4 1 Refer to Factory 5 ISSUE No Heat while machine running POSSIBLE CAUSES 5 1 F1 F4 Fuses Blown 5 1 1 Inspection by qualified personnel required 5 1 2 Needs to be replaced 5 2 MC1 4 Failure 5 2 1 Needs to be replaced 5 3 Heater Failure 5...

Page 33: ...7 3 1 Needs to be replaced 7 4 5A Fuse Blown F8 600435 7 4 1 Needs to be replaced 8 ISSUE Engine Starter will not engage after Pre Start alarm POSSIBLE CAUSES 8 1 Wait to Start required by Engine ECM 8 1 1 See indicators on HMI and refer to Screen Layout 8 2 25A Fuse blown P09 600449R0 8 2 1 Needs to be replaced 8 3 5A Fuse Blown F8 600435 8 3 1 Needs to be replaced 8 4 Engine Starter Failure 8 4 ...

Page 34: ...ce information for your engine Top level maintenance is provided in this section For detailed engine maintenance procedures please refer to the engine manufacturers operation and maintenance manual supplied with your heater There you will find a full range of maintenance procedures and maintenance scheduling Oil Viscosity 33 ...

Page 35: ...DATE HOURS SERVICED BY SERVICE PERFORMED Maintenance Record 34 ...

Page 36: ...Change X Grease Axle Hubs Service X Torque Wheel Nuts 120 ft lbs Check X Service Parts Description Part Number Type Engine Oil see oil viscosity chart Engine Oil Filter 441 6852 Engine Air Filter inner 110 6331 Engine Air Filter outer 110 6326 Engine Fuel Filter Element 360 8960 Engine Fuel Water Separator Element 311 3901 Refer to engine manual for greater detail 35 Caterpillar Engine ...

Page 37: ... filter Change Grease Axle Hubs Service X Torque Wheel Nuts 120 ft lbs Check X Service Parts Description Part Number Type Engine Oil see oil viscosity chart Engine Oil Filter 0117 4416 Engine Air Filter inner 0118 0871 Engine Air Filter outer 0131 9258 Engine Fuel Filter 0413 7456 Engine Fuel Water Separator 0413 0241 Refer to engine manual for greater detail 36 Deutz Engine ...

Page 38: ... Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to the engine components Air cleaner ele ments help to prevent airborne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the ...

Page 39: ... Filter hood 3 Outer air filter 4 Inner air filter 5 Hexagon nut Maintaining the Air filter NOTICE Do not clean the air filter with chemicals or hot liquids Maintain the filter elements according to the interval in the maintenance schedule Lift the clamps to open the housing Pull out the filter element blow out with compressed air from the inside to the outside if soiling is only slight Replace if...

Page 40: ...cts the filter head surface Tighten the fuel filter an additional turn after contact or consult the filter manufacturer instruc tions Prime fuel system after filter installation WARNING The fuel pump high pressure fuel lines and fuel rail contain very high pressure fuel Never loosen any fittings while the engine is running Personal injury and property damage can result To prime the engine use the ...

Page 41: ...nnection Loosen drain plug and drain liquid Dissasemble filter insert Clean any dirt off of the sealing surfaces Wet the sealing surfaces of the filter car tridge with fuel and screw back on to the filter head clockwise Tighten drain plug Connect electrical connection Prime the fuel system Priming the Fuel System NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starti...

Page 42: ... plug Connect electrical connection Vent the fuel system Priming the Fuel System NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before crank ing the engine again Ensure the fuel system is in working order and the supply valve is in the on position if equipped Operate the hand priming pump Count the number of operations of the p...

Page 43: ...bricating oil Change the lubricating oil and filter at the specified oil change interval See the maintenance schedule to find the correct change interval for your application 1 Operate the engine until the temperature reaches 80 C 176 F 2 Shut off the engine 3 Position drain pan under the oil drain plug 4 Remove the oil drain plug Drain the oil immediately to be sure all the oil and suspended con ...

Page 44: ... lubricating oil to the gasket sealing surface before installing the filter NOTE Be careful the no debris is poured into the filter If using an oil supply with a metallic or plastic seal under the cap be careful to peel the seal back Punching the seal with a knife or sharp object can create debris in the oil container CAUTION Mechanical overtightening of the filter can distort the threads or damag...

Page 45: ...rface Use a new sealing washer if damaged Install the lubricating oil pan plug CATERPILLAR ENGINE DEUTZ ENGINE Fill the engine with clean lubricating oil to the proper level Idle the engine to inspect for leaks at the drain plug and if replaced the oil filter seal NOTE Engine oil pressure must be indicated on the gauge within 15 seconds after starting If oil pressure is not registered within 15 se...

Page 46: ...r Element 480V Electric Trailer and Fuel Tank Axles 2 5000 Lb With Electric Brakes Tires ST225 75R 15 6 Bolt Tire Inflation Pressure 80 PSI Wheel Nut Torque 120 FT LBS Hitch 2 5 16 Ball or Pintle Tie Downs 4 For Transporting Fuel Tank Capacity 192 US Gallons Ground Clearance 9 Containment 110 Nominal Heat Output 572 000 BTU H Fuel Requirement 1 or 2 Diesel Fuel Fuel Consumption 4 5 GPH MAX Run Tim...

Page 47: ...ousness and possibly death Inhalation can also cause irritation of nose and throat Aspiration of liquid drops into the lungs may produce potentially fatal chemical pneumonitis fluid in the lungs severe lung damage or respiratory failure For more information refer to Section 11 Potential Health Effects DO NOT induce vomiting because of danger of aspirating liquid into lungs Seek medical attention E...

Page 48: ...O NOT ingest Do not breathe gas vapour spray In case of insufficient ventilation wear suitable respiratory equipment If ingested seek medical advice immediately Avoid contact with skin and eyes Practice good personal hygiene Wash hands after handling and before eating Launder work clothes frequently Discard saturated leather goods Handling Section 7 Handling and Storage Engineering Controls Person...

Page 49: ...o contain any chemicals at reportable quantities that are listed as group 1 2A or 2B carcinogens by IARC ACGIH Notice of Intended Changed 2000 proposed A3 animal carcinogen Diesel oil This product is not expected to be a teratogen or an embryotoxin based on the available data and the known hazards of the components This product is not expected to be a reproductive hazard based on the available dat...

Page 50: ...rmation 905 804 4752 For Copy of MSDS Glossary ACGIH American Conference of Governmental Industrial Hygienists ADR Agreement on Dangerous goods by Road Europe ASTM American Society for Testing and Materials BOD5 Biological Oxygen Demand in 5 days CAN CGA B149 2 Propane Installation Code CAS Chemical Abstract Services CEPA Canadian Environmental Protection Act CERCLA Comprehensive Environmental Res...

Page 51: ...AWG BLACK 10AWG BLACK 10AWG BLACK F2 Rating 600Vac 25A Type CC Fast Acting L1 L1 L2 L2 L3 L3 10AWG BLACK 10AWG BLACK 10AWG BLACK L1 L2 L3 T1 T2 T3 MC2 F1 Rating 600Vac 25A Type CC Fast Acting L1 L1 L2 L2 L3 L3 10AWG BLACK 10AWG BLACK 10AWG BLACK L1 L2 L3 T1 T2 T3 MC1 14AWG BLACK 14AWG BLACK MANUFACTURER MAX VOLTAGE PHASE FLA HZ 60 73 1A 3 DAKOTA FLU ID POWER 480VAC LARGEST MOTOR FLA SHORT CIRCUIT ...

Page 52: ... 2 F8 Rating 125VDC 5A F8_B A B F9 Rating 125VDC 10A F9_B A B F10 Rating 125VDC 15A F10_B A B 22 21 24 R2 A2 A1 R2 FAULT 12 12 11 11 14 14 LM1_24 LM1_21 LM1_14 LM1_11 R2_11 R2_14 R2_11 R2_14 A2 A1 R3 RUN 12 12 11 11 14 14 R3_11 R3_14 A2 A1 R1 INTAKE 12 12 11 11 14 14 R1_11 R1_14 A2 A1 R5 GATE CLOSE 12 12 11 11 14 14 R5_11 R5_14 A2 A1 R4 GATE OPEN 12 12 11 11 14 14 R4_11 R4_14 R5_12 12V 0V 12V 0V 1...

Page 53: ...AS A WHOLE WITHOUT THE WRITTEN PERMISSI ON OF DAKOTA FLUID POWER IS PROHIBITED JMA 11 Jun 2019 ISSUED DRAWN WIRE TYPE GXL or SXL LOCATION 120 TITLE 600435 3 OF 3 DRAWING NO SHEET LAYOUT PS1 WIRE WAY DC COMPONENT ASSEMBLY WIRE WAY WIRE WAY WIRE WAY LM1 F10 F9 F8 F7 R1 R2 R3 R4 R5 TERMINAL BLOCKS GND DSC1 F6 F5 F4 F3 F2 F1 MMP1 MC5 MC4 MC3 MC1 MC2 WIRE WAY HMI PRINT POCKET PANEL HARNESS ENCLOSURE 36...

Page 54: ...SOCKET IDENTITY PLUG DESCRI PTION P01 DT06 2S P012 INTAKE VALVE PIN COLOR SIZE DESCRI PTION LOCATION 1 2 BLK WHT INTK_VALVE_GND INTK_VALVE_SIGNAL P03_08 P03_07 ITEM QTY PART NUMBER DESCRI PTION SOCKET CAVITY PLUG WEDGELOCK 4 8 1 LA2702000 LA2700500 LA6414000 18 16AWG RED 12P SOCKET IDENTITY PLUG DESCRI PTION P02 DT06 12SA CE02 ENGINE 3 7 8 10 WHT YE TP GR TP WHT START J1939_HI J1939_LO IGNITION P0...

Page 55: ...P02_A SPL_04 P02_B P03_04 SPL_02 SPL_03 P03_05 P03_06 14 14 P01 ENGINE P02 DIAG PLUG 136 30 2 ITEM QTY PART NUMBER DESCRI PTION PIN CAVITY PLUG WEDGELOCK 6 6 1 LA2701000 LA2700500 LA6412000 20 16AWG RED 12P RECPT IDENTITY PLUG DESCRI PTION P03 DT04 12PA CE02 CHASSIS 3 4 5 6 7 8 WHT WHT YE TP GN TP WHT BLK IGNITION START J1939_HI J1939_LO INTK_VALVE_SIGNAL INTK_VALVE_GND SPL_03 P01_F P01_V P01_X P0...

Page 56: ...1 888 757 3545 support tamarack ind com 1 320 759 1583 WWW THAWZALL COM 2736 Latoka Lane SW Unit B Alexandria MN 56308 USA ...

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