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171

E 3000

Troubleshooting

 

10.2

Troubleshooting the Oil Burner

  

Problem / Symptom

Reason

Remedy

The burner does not start.

Improper switch position or 
protective function action.

Verify that the breaker is 
ON. Verify that the HTF 
level is within range and low 
level shutdown device is 
reset (low level indicator 
light must be OFF).

The over-temperature limit 
has tripped.

Allow the burner to cool.

The burner primary control 
is in lockout mode.

Reset the burner control.

The burner starts; the flame 
does not ignite.

There is no fuel.

Fill fuel tank.

The burner nozzle is dam-
aged or worn.

Replace the burner nozzle.

The electrodes are defec-
tive.

Replace the electrodes.

The cadmium cell is mal-
functioning.

Replace the cadmium cell.

The burner primary control 
is malfunctioning.

Replace the burner primary 
control.

The burner starts and the 
flame ignites, but the unit 
locks out.

The fuel pressure is set 
incorrectly.

Adjust the fuel pressure.

The burner nozzle is dam-
aged or worn.

Replace the burner nozzle.

The air damper is set incor-
rectly.

Adjust the air damper.

The cadmium cell is mal-
functioning.

Replace the cadmium cell.

The burner primary control 
is malfunctioning.

Replace the burner primary 
control.

Combustion is poor or 
noisy.

There is a lack of fresh air 
to burner.

Ensure there is an ade-
quate air supply.

Summary of Contents for E 3000 LB

Page 1: ...Operator s Manual Hydronic Surface Heater E3000 Type E3000 Document 5000188154 Date 1115 Version 05 Language EN 5 0 0 0 1 8 8 1 5 4 ...

Page 2: ... 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 ...

Page 3: ...ty 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 o...

Page 4: ...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 Neus...

Page 5: ...odifications 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 dama...

Page 6: ...Foreword wc_tx002028gb fm 6 ...

Page 7: ...Locations 22 2 2 Label Meanings 24 3 Lifting and Transporting 30 3 1 Lifting the Machine 30 3 2 Preparing the Machine for Transport on a Truck or Trailer 31 3 3 Transporting the Machine on a Truck or Trailer 32 3 4 Before Towing Checklist 34 3 5 Towing the Machine 35 3 6 Testing the Breakaway System Electric Brakes 36 3 7 Hazardous Materials Placards 38 4 Operation 40 4 1 External Components 40 4 ...

Page 8: ... the Beckett Burner Controller 73 5 Accessories 78 5 1 Available Accessories 78 5 2 Expanding the Surface Heating Capacity 79 5 3 Expanded Operation Using One HHS 3002 and One DPP 80 5 4 Expanded Operation Using Two HHS 3002 and Two DPP 82 5 5 Mounting and Connecting the Auxiliary Pump Panel 85 5 6 Using Heat Exchangers to Heat Air 87 5 7 Connecting Six HX 50 Heat Exchangers 88 5 8 Connecting Five...

Page 9: ...ion Head 129 7 9 Checking the Supply Gas Pressure 130 7 10 Checking and Adjusting the Burner Gas Pressure 132 8 Maintenance 134 8 1 Periodic Maintenance Schedule 134 8 2 Inspecting the HTF System and the Fuel System 135 8 3 Repairing a Hose 136 8 4 Inspecting the Electrical Components 138 8 5 Filling the HTF Reservoir 140 8 6 Cleaning the HTF Strainer 142 8 7 Replacing the Fuel Filter 144 8 8 Lubr...

Page 10: ...the Gas Burner 172 11 Technical Data 173 11 1 Machine 173 11 2 Trailer 174 11 3 Dimensions 174 MSDS Dowfrost HD 50 175 Fuji Temperature Controller 183 Tire Safety Information 187 12 Schematics 200 12 1 Composite Schematic Machine with Oil Burner 200 12 2 Composite Schematic Machine with Gas Burner 201 12 3 Electrical Schematic Components 202 12 4 Circulation System Circuit 205 12 5 Rewind System C...

Page 11: ... 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 ...

Page 12: ...rmanently 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 anythin...

Page 13: ...chine 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 i...

Page 14: ...ine 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 4 Safety Guidelines for Lifting the Machine When lifting the machine Make sure slings chains hooks ramps jacks forklifts cranes hoists and any other t...

Page 15: ...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 Ne...

Page 16: ...ou 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 Re...

Page 17: ...ge of the tools and equipment attached to the genset must not exceed the load rating of the genset Do not operate the genset with wet hands Do not remove the radiator cap when the genset is running or is hot Refueling safety When adding fuel to the fuel tank Do not smoke Do not refuel a hot or running engine When adding fuel to the fuel tank Keep sparks flames electrical arcs and other sources of ...

Page 18: ...tments 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 onl...

Page 19: ... 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 Maintenance guidelines When maintaining the machine Keep the fuel lines in good condition and properly connected Allow the burner to cool before mai...

Page 20: ...operly inflated Only tow the machine when all trailer lights are functioning correctly Only tow the machine when the trailer s safety chains are connected to the towing vehicle in a crisscross pattern Maintain extra distance between the towing vehicle and other vehicles Avoid soft shoulders curbs and sudden lane changes Abide by all licensing requirements for your area If you have not driven a tow...

Page 21: ...en an investigation and if it finds that a safety defect exists in a group of trailers it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Wacker Neuson To contact NHTSA you may either contact the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar gov or write to Administrator NH...

Page 22: ...Labels E 3000 wc_si000643gb fm 22 2 Labels 2 1 Label Locations 603 wc_gr008850 998 608 626 602 601 999 618 ...

Page 23: ...E 3000 Labels wc_si000643gb fm 23 616 625 613 613 602 626 619 995 625 608 616 609 607 612 617 600 613 604 612 618 609 602 611 wc_gr008849 ...

Page 24: ...additives or a 50 50 blend of 2 diesel and K1 kerosene plus addi tives when temperatures are below 5 F 15 C Use a 70 30 blend of 2 diesel and 1 diesel plus additives or a 70 30 blend of 2 diesel and K1 kerosene plus additives when temperatures are in the range 5 to 25 F 15 to 4 C Use a winter blend diesel when temperatures are above 25 F 4 C For machines powered by the power utility Use 100 1 dies...

Page 25: ...Fluid This label is located adjacent to a sight gauge on the Heat Trans fer Fluid reservoir 604 WARNING Do not engage trailer jack while transporting the machine Refer to the Operator s Manual for further instructions 607 Do not reset Refer to Operator s Manual Ref Label Definition WARNING WARNUNG ADVERTENCIA AVERTISSEMENT 173200 173201 ...

Page 26: ...nt Attach lifting device in this location 611 WARNING Hand entanglement hazard Moving parts can crush and cut Do not operate with guard removed 612 CAUTION Hot surface hazard Ref Label Definition CAUTION VORSICHT PRECAUCION PRECAUTION WARNING WARNUNG ADVERTENCIA AVERTISSEMENT 173224 ...

Page 27: ...achine uses diesel fuel 618 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 Ref Label Definition 8582 3900 ...

Page 28: ...y torqued before trans porting Failure to heed above warning could result in wheel loss which can cause injury or death 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 Ref Label Definition ...

Page 29: ...plate 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 Ref Label Definition CAUTION VORSICHT ATENCION ATTENTION 183255 5200002911 Never operate in an explosive environment or near flammable vapors fuels or combustibles Explosion or fire may occur Risk of sever...

Page 30: ... 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 ...

Page 31: ...r trailer are chocked during the loading process Check that the transport vehicle or trailer is clean and free of grease oil ice and other loose material If the machine is mounted to a trailer check that the jackstand or other transport block piece of wood or other similar material is available to support the trailer tongue during transporting Do not use the machine s trailer jack to support the t...

Page 32: ...ramps or docks NOTICE The flat bed must be at least 98 inches wide Support the tongue 2 Raise the tongue using the trailer jack a 3 Install the tongue support b using two 5 8 inch bolts NOTICE If the supplied tongue support is missing use any mechanism capable of supporting the tongue weight 4 Lower the tongue and retract the trailer jack a at least two inches from the surface of the truck bed Thi...

Page 33: ...ting and Transporting Continued from the previous page Secure the machine 5 Install properly rated securing mechanisms d such as chains or straps 6 Install chocks e under all four wheels Result The machine is ready to be transported ...

Page 34: ... fresh grease applied to it Wheels Check that all lug nuts are in place and are properly torqued Check the tread wear of the tires Check that the tires are inflated to the proper pressure Trailer operation Check that the directional and running lights on the trailer function correctly Check that the safety chains of the trailer are connected to the towing vehicle using a crisscross pattern Check t...

Page 35: ...pic Stopping and Packing Up the Machine 3 Adjust the amount of fuel in the machine to approximately 70 capacity to avoid fuel spillage 4 Complete the Before Towing Checklist See topic Before Towing Checklist 5 Connect the machine to the towing vehicle 6 Rotate the trailer jack to a horizontal position 7 Tow the machine as needed WARNING Risk of severe injury or death Improperly torqued lug nuts ca...

Page 36: ...chine trailer to the tow vehicle 2 Disconnect the trailer wiring plug a from the tow vehicle 3 Pull the breakaway pin b out of the brake switch c to activate the brakes and attempt to tow the machine trailer at a very slow speed less than 5 mph 8 km hr When activated a properly working breakaway system will cause substantial drag on the trailer wheels and may even cause the trailer wheels to lock ...

Page 37: ... or recharge the breakaway battery 6 If 12 14 VDC was measured but the brakes did not function there is a wiring or mechanical fault with the brakes Repair any faults before towing 7 If the brakes function properly a Reconnect the wires to the breakaway battery b Reinstall the cover to the battery box a Reinstall the breakaway pin b into the brake switch b Connect the trailer wiring plug to the to...

Page 38: ... Before transporting the machine 1 Drain and purge the fuel tank of all fuel and fuel residue OR place placards that display the numeric hazardous material code for diesel fuel on three sides of the machine Note The placards are included with the machine 2 Consult the Department of Transportation DOT or equivalent agency in the states or countries in which this machine is to be transported regardi...

Page 39: ...ghi_tx001160gb fm 39 E 3000 Lifting and Transporting Notes ...

Page 40: ...1 External Components wc_gr008851 1 3 7 8 9 4 10 6 2 5 Ref Description Ref Description 1 Hitch ball or pintle 6 Fender 2 Tie down 7 Onan genset option 3 Fuel tank 8 Jack stand 4 Fuel tank cap 9 Tandem axles 5 Performance monitoring light 10 Lifting bail ...

Page 41: ...lations applicable to pressurized boilers Ref Description Ref Description a Hydronic heater1 h Fill valve 3 b Burner oil burning shown i HTF pumps c Suction valve 2 j Low level shut down device d Fuel filter k Thermocouple e Battery l Temperature pressure gauges f Fuel sight gauge m HTF filter g Fuel sight gauge valve n Motor HTF pump wc_gr008296 g ...

Page 42: ...ol panel g Hose reels and hose b Heat Transfer Fluid HTF return plumbing h Pump Pack supply connections c HTF supply plumbing i Duplex receptacle d Hose reel brake T handle j Operator s Manual holder e Rewind system foot control pedal k Thermal switch snap switch f HTF expansion tank sightglass k ...

Page 43: ...Accessory HTF return thermometer d Main HTF return thermometer e Check valves f Pump pressure gauge g Right pump Valve Description 1 Pump Pack supply and drain valve 2 Pump suction valve behind hose reel 3 HTF fill valve behind hose reel 4 Left hose reel supply valve 5 Cross connect valve 6 Right hose reel supply valve 7 Pump Pack supply valve ...

Page 44: ...wc_tx001951gb fm 44 Operation E 3000 4 5 Control Panel wc_gr008606 1 2 n d e f g h i j k l m a b c o p ...

Page 45: ...FF switch Switches electric power ON and OFF to the burner i Pump 2 ON OFF switch Switches electric power ON and OFF to Pump 2 j Pump 1 ON OFF switch Switches electric power ON and OFF to Pump 1 k HTF fill switch This momentary switch bypasses the low level shut down device and provides power to the pumps It is used when filling the HTF reservoir after a low level fault l Low level fault indicator...

Page 46: ... 4 7 Genset Control Panel Ref Description a Oil fill cap and dipstick b Coolant recovery access panel c Coolant level sightglass d Control switch and status light e Line circuit breakers f Coolant fill access panel f a b c e d wc_gr008140 ...

Page 47: ... oil and battery acid 6 Move the machine to its operating location 4 9 Breaking in the Genset Background New gensets require a break in period for the engine If you are the first owner of this machine or the genset s engine has just been rebuilt break in the engine as stated below Procedure 1 Check that the engine oil level is correct Check that the engine oil viscosity is appropriate for the temp...

Page 48: ...efore daily operation 4 11 4 15 2 Check fuel level 4 13 4 15 3 Position the machine At the job site 4 14 4 Perform pre starting checks 4 15 5 Connect power 4 16 6 Start the generator if equipped 4 17 7 Power up the machine 4 18 8 Run the machine a Preheat the HTF if necessary 4 19 b Initiate HTF flow 4 20 c Unwind and position the hoses 4 22 4 23 d Monitor the operating parameters 4 24 e Rewind th...

Page 49: ...chine is cool Procedure The Heat Transfer Fluid HTF level must be between the marks on the sightglass c If low If the HTF level is low HTF must be added Filling the HTF reservoir requires electric power to the machine and knowledge of the machine s operation Familiarize yourself with the function of the machine s controls then see topic Filling the HTF Reservoir for detailed instructions ...

Page 50: ...uel Blend Guide Lowest expected ambient temperature F C Generator powered Shore powered Below 5 15 50 50 blend of 2 diesel and 1 diesel plus additives OR 50 50 blend 2 diesel and K1 kerosene plus additives 100 1 diesel plus additives OR 100 K1 kerosene plus additives 5 to 25 15 to 4 70 30 blend of 2 diesel and 1 diesel plus additives OR 70 30 blend of 2 diesel and K1 kerosene plus additives Above ...

Page 51: ... lever a on the fuel cap 2 Rotate the lever counterclockwise until it stops 3 Remove the fuel cap from the tank 4 Fill the tank with the appropriate grade of fuel for the weather conditions until the gauge b reads full Leave room within the tank for possible fuel expansion 5 Reinstall the fuel cap Result The procedure to refuel the machine is now complete wc_gr008446 a wc_gr008447 wc_gr008448 wc_g...

Page 52: ...close to any combustible material or flammable vapor so that all of the machine s access doors panels may be accessed so that HTF hoses do not pose tripping hazards and so the HTF hoses cannot be damaged by machines or other equipment on the job site This procedure continues on the next page DANGER Asphyxiation hazard Exhaust gas from the burner contains carbon monoxide a deadly poison you cannot ...

Page 53: ...wing procedure to position the machine 1 Place the machine near the application area a on solid stable and level ground 2 For machines with trailers install chocks b under the wheels Result The machine is now properly positioned T I E D O W N T I E D O W N T I E D O W N T I E D O W N wc_gr008529 b ...

Page 54: ...ne Checks Before starting the machine check the following items Fuel System Fuel sight gauge valve a f Check that the fuel sight gauge valve is open Fuel sight gauge b f Check that the fuel tank is full Quick connects d f Check that the quick con nect couplings are secure Heat Transfer Fluid HTF System wc_gr008602 b a wc_gr008605 d ...

Page 55: ...with the locking pin NOTICE The HTF fill valve must remain closed and locked during normal operation An open HTF fill valve will cause HTF leakage HTF sight gauge c f Check that the HTF level is within the operating range NOTICE Starting the machine with low HTF will damage the pumps HTF Hose connections e f Check that all HTF hose quick connects are secure ...

Page 56: ... have power applied Hydronic heater f f Inspect for signs of exhaust leaks See topic Inspecting Replacing the Rope Gasket Genset g if equipped f Check oil level See topic Checking the Engine Oil f Inspect for signs of fuel and exhaust leaks wc_gr008603 f wc_gr008141 g ...

Page 57: ... gauge extension cords for lengths up to 30 m 100 ft Procedure Follow the procedure below to connect power to the machine 1 Move both circuit breaker switches a and b to the OFF position 2 Connect the main power cords c to a properly rated power source or to the generator d if included Result Power has now been connected WARNING Fire hazard and electric shock hazard The use of undersized extension...

Page 58: ...stem Press and hold the control switch in the Stop Prime position The fuel pump will start two seconds after the control switch is initially placed in the Stop Prime position Continue holding the control switch for at least one minute 3 Press and hold the control switch in the Start Preheat position The genset will first preheat for up to 15 seconds depending on how cold it is Then the starter wil...

Page 59: ...button of the GFCI if its indicator light is ON 3 Check that the low level fault indicator light c is OFF If this light is ON add Heat Transfer Fluid HTF to the reservoir See topic Filling the HTF Reservoir 4 Check that the displays of the temperature controller d illuminate If the displays of the temperature controller do not illuminate there is a problem with the GFCI 1 or with the wiring to the...

Page 60: ...100 F 40 C This is the set point temperature 2 Move the burner ON OFF switch b to the ON position The following sequence occurs a The burner motor starts after a 5 second delay b The burner fires after a 15 second delay c The burner will operate with little or no visible exhaust smoke until the HTF reaches the set point temperature at which time the burner will stop firing d The burner will re fir...

Page 61: ...ure below to initiate HTF flow 1 Close and lock valve 3 This is the fill valve v 2 Open valve 2 This is the suction valve 3 Open valve 4 and valve 6 These are the hose reel supply valves This procedure continues on the next page CAUTION Burn hazard The hoses and components of the plumbing system may be very hot Hot hoses and hot plumbing components may cause burns f Wear gloves when handling hot h...

Page 62: ...e 125 140 psi 8 6 9 6 bar When the HTF is warm operating pressure should be 90 110 psi 6 2 7 6 bar 6 Check the HTF flow indicator f The flow indicator should be spinning If it is not there is a problem Shut down the machine and rectify the problem before continuing 7 Repeat steps 4 6 for the right pump Result HTF is now flowing 4 21 Setting the Operating Temperature Operating temperature Once the ...

Page 63: ...ication area See topic Hose Spacing Guidelines for hose spacing recommendations based on application Result The hose is now positioned and the machine is operating NOTICE The machine must be periodically monitored during operation to ensure system efficiency See topic Monitoring the Operating Parameters CAUTION Burn hazard The hoses and components of the plumbing system may be very hot Hot hoses a...

Page 64: ...at penetration cover the hoses with a plastic vapor barrier and two layers of insulated blankets For concrete curing cover the concrete with plastic place the hoses on top of the plastic then cover the hoses with two layers of insulated blankets Note The hoses may be positioned vertically along concrete framing walls for curing applications Contact Wacker Neuson Application Support for more inform...

Page 65: ...F operating pressure Operating pressure 90 110 psi If operating pressure is higher than 110 psi check for kinked hoses If operating pressure is less that 90 psi check HTF level HTF return temperature The HTF return temperature tells you how much heat is being transferred It can also tell you when a thawing pro cess is complete as very little heat will be transferred at that point Consult Wacker Ne...

Page 66: ... Move the hose rewind ON OFF switch c to the RIGHT or LEFT position depending which reel you are working with Note The rewind motor will start but will not rotate the hose reel until the clutch is engaged 4 Press down on the foot pedal to engage the clutch The hose reel will rotate 5 Guide the hose evenly onto the hose reel as it rotates This procedure continues on the next page CAUTION Burn hazar...

Page 67: ...d 7 Manually wind the remainder of the hose onto the reel 8 Engage the hose reel brake by turning the T handle a clockwise 9 Return the foot pedal b to its storage location 10 Turn the pump off 11 Move the hose rewind ON OFF switch c to the OFF position Result The hoses are now wound onto the hose reel and the machine is ready to be shut down See topic Shutting Down and Packing Up the Machine wc_g...

Page 68: ...OFF position 4 Move the pump ON OFF switches b1 and b2 to the OFF position 5 Move the circuit breaker ON OFF switches e to the OFF position The machine is now shut down and ready to be packed up Packing up the machine Perform the following procedure to pack up the machine 1 Disconnect and store all accessories 2 Disconnect power from the machine 3 Close and lock all doors Result The machine is now...

Page 69: ...city During a low HTF level condition the following occurs The control panel low level fault light illuminates Power is cut to the burner Power is cut to the pumps The low level shut down device LOW WATER light illuminates Procedure Follow the procedure below to reset a low HTF fault 1 Move the burner switch to the OFF position 2 Move the pump switches to the OFF position 3 Clean the fill hose 4 R...

Page 70: ...occur The POWER green f and LOW WATER red e lights will blink for fif teen seconds while the low level shut down device performs a self diagnos tic test After 15 seconds the LOW WATER light will go out the POWER light will stay on The low HTF level indicator will go out Power will be returned to the pumps Power will be returned to the burner 9 Move the right pump switch to the ON position I and co...

Page 71: ...er and allow any HTF within the hose to drip back into the container Cap the fill hose if a cap is provided 12 Move the fill hose to its storage location under the hose reel 13 Open valve 2 and close valve 3 simultaneously Result The low HTF level fault has been reset and the HTF reservoir has now been filled You may now resume operation of the machine ...

Page 72: ...an water 2 When the couplings are clean inspect seals and gaskets and replace them if necessary 3 After cleaning the couplings install caps or protective covers on the couplings to protect them Using Follow the procedures below to use the quick connect couplings 1 Pull back and hold the locking collar c on the female coupling b 2 Insert the male coupling a into the female coupling 3 Release the lo...

Page 73: ...cuit between the two terminals labeled T of the burner control This is the call for heat The burner control enters the valve on delay state The valve on delay state lasts 15 seconds During this state Power is sent to the burner motor fuel pump Power is sent to the electrodes If the cad cell detects flame at the end of the valve on delay state the burner control goes into the lockout state Trial fo...

Page 74: ...psed During this state The fuel shut off valve is open energized Pressurized fuel atomizes at the burner nozzle The flame is monitored by the cad cell When the setpoint is reached call for heat satisfied the burner control enters the burner motor off delay state If the flame is lost during the run state The burner control enters the recycle mode Burner motor off delay The burner motor off delay st...

Page 75: ... clear the soft lockout fault so a restart can be attempted press and release the reset button Note After the third attempt to manually clear the lockout fault the burner control will enter the hard lockout mode To clear the hard lockout press and hold the reset button for 15 seconds wc_gr007665 Yellow pump prime Green flame recycle Red Reset button lockout State Action or Function Recycle The bur...

Page 76: ...lve Use a suitable container to collect the purged oil 2 Set the temperature controller so there is a call for heat 3 After the burner starts press and hold the reset button for 15 seconds until the yellow light turns on then release the reset button The yellow light will turn off the burner control pow ers down the burner and the burner will then start up again At burner startup press and release...

Page 77: ...wc_tx001951gb fm 77 E 3000 Operation Notes ...

Page 78: ...awing and curing capacities of the parent machine Covering the heat transfer hoses with insulation blankets increases heat retention and penetration The 1 2 and 2 1 adapters and accessory hoses allow the accessories to be properly connected to your parent machine For compatibility and configuration information continue reading Ref Description Ref Description a Hose Handling System HHS3002 f 1 2 Ad...

Page 79: ...hine is capable of the following when utilizing the expansion configurations illustrated below Option 1 E 3000 combined with one HHS 3002 a and one DPP b Option 2 E 3000 combined with two HHS 3002 s a and two DPP s b Note This configuration requires installing an Auxilliary Pump Panel for power protection See topic Mounting the Auxiliary Pump Panel For more information regarding setup of these con...

Page 80: ...el of the E 3000 within the application area 5 Unwind and position the hose loop 1 d from the HHS 3002 f within the application area a Connect the male quick connect to the return port g b Connect the female quick connect to the DPP a 6 Unwind and position the hose loop 2 e from the HHS 3002 c within the application area Place the HHS 3002 frame in a safe place a Connect the male quick connect to ...

Page 81: ...sed no connections a DPP Connected to E 3000 and HHS 3002 b Hose loop from left reel Placed in application area c Hose loop from right reel Placed in application area d HHS 3002 hose loop 1 Placed in application area e HHS 3002 hose loop 2 Disconnected from HHS 3002 hose loop 1 and placed in application area f HHS 3002 frame Placed in safe location g Return port Used for HSS 3002 loop 1 h Return p...

Page 82: ... Unwind and position the hose loop 2 e from the HHS 3002 f within the application area Place the HHS 3002 frame in a safe place a Connect the male quick connect to the 2 1 adapter j b Connect the female quick connect to the DPP a 9 Unwind and position the hose loop 1 k from the second HHS 3002 n within the application area a Connect the male quick connect to the 2 1 adapter i b Connect the female ...

Page 83: ...ghi_tx001162gb fm 83 E 3000 Accessories Continued from the previous page This procedure continues on the next page wc_gr008542 g i f n j h b c k l d e m y x ...

Page 84: ...3002 hose loop 1 Placed in application area e First HHS 3002 hose loop 2 Disconnected from first HHS 3002 hose loop 1 and placed in application area f First HHS 3002 frame Placed in safe location g Return port Used for HSS 3002 loop 1 h Return port Used for HHS 3002 loop 2 i j 2 1 adapter Connected to return port k Second HHS 3002 hose loop 1 Placed in application area l Second HHS 3002 hose loop ...

Page 85: ...ems to provide protection for any additional Pump Packs that are connected to the machine If the machine experiences a low level fault condition the APP will cut off power to the external components This power cut off protects the pumps from damage Guidelines Follow the guidelines below when mounting the APP Refer to the diagram below Install inside the machine near the main control panel a Instal...

Page 86: ...lete the electrical connections 1 Connect the DIN leader a from the main control panel to the corresponding DIN leader on the APP b 2 Connect a properly rated extension cord c to the power cord d on the APP 3 Connect the Pump Pack power cord f to the APP power adapter e Result The APP is now mounted and connected Continue with normal operation ...

Page 87: ... to determine what components may be required NOTICE Use care when adding accessories failure to adhere to these require ments may damage your machine Limitations Maximum run horizontal distance from HX to machine 228 m 750 ft Maximum rise vertical distance of HX above machine 76 m 250 ft Maximum run at maximum rise 215 m 707 ft Note The farther the HX is positioned from the parent machine the mor...

Page 88: ...near the machine 2 Connect hose i to the supply port of the SPP and to valve 1 of the machine 3 Connect a 1 2 adapter h to the outlet port of the SPP 4 Open valve 1 Connect the HX hoses 1 Position the Heat Exchangers a thru f within the space to be heated 2 Connect Heat Exchanger a to 1 2 adapter z and 2 1 adapter x 3 Connect Heat Exchanger b to 1 2 adapter z and 2 1 adapter y 4 Connect Heat Excha...

Page 89: ...en the Heat Exchangers are not connected will cause excess system pressure which may damage the pumps 1 Start the E 3000 and operate it with the temperature controller set to 180 F 80 C 2 Turn on the Heat Exchangers and adjust the thermostats as desired wc_gr008556 2 1 2 1 2 1 2 1 1 2 1 2 1 2 g h i x w v u z y a b c d e f LR RR RS LS HX 50 HX 50 HX 50 HX 50 HX 50 HX 50 SPP APP ...

Page 90: ...on the Heat Exchangers a thru e within the space to be heated 2 Connect Heat Exchanger a to 1 2 adapter z and 2 1 adapter x 3 Connect Heat Exchanger b to 1 2 adapter z and 2 1 adapter y 4 Connect Heat Exchanger c to 1 2 adapter v and 2 1 adapter y 5 Connect Heat Exchanger d to 1 2 adapter v and 2 1 adapter w 6 Connect Heat Exchanger e to SPP and 2 1 adapter w Complete the installation 1 Insulate t...

Page 91: ...ghi_tx001162gb fm 91 E 3000 Accessories wc_gr008557 APP 2 1 2 1 2 1 1 2 1 2 g i x w v z y a b c d e LR RR RS LS HX 50 HX 50 HX 50 HX 50 HX 50 SPP ...

Page 92: ...pter z and 2 1 adapter x 3 Connect Heat Exchanger b to 1 2 adapter z and 2 1 adapter x 4 Connect Heat Exchanger c to 1 2 adapter v and 2 1 adapter y 5 Connect Heat Exchanger d to 1 2 adapter v and 2 1 adapter y Complete the installation 1 Insulate the supply and return hoses 2 Connect the Heat Exchangers to the appropriate electrical source 3 Open cross connect valve 5 4 Close valve 4 and valve 6 ...

Page 93: ...ghi_tx001162gb fm 93 E 3000 Accessories wc_gr008558 2 1 2 1 1 2 1 2 x v z y a b c d LR RR RS LS HX 50 HX 50 HX 50 HX 50 ...

Page 94: ...to 1 2 adapter z and 2 1 adapter x 4 Connect Heat Exchanger c to right accessory supply RS 5 Connect Heat Exchanger c to return plumbing rack RR Complete the installation 1 Insulate the supply and return hoses 2 Connect the Heat Exchangers to the appropriate electrical source 3 Open cross connect valve 5 4 Close valve 4 and valve 6 Run the machine NOTICE Only start the pumps when the Heat Exchange...

Page 95: ...ghi_tx001162gb fm 95 E 3000 Accessories wc_gr008559 2 1 1 2 x z a b c LR RR RS LS HX 50 HX 50 HX 50 ...

Page 96: ...rack RR Complete the installation 1 Insulate the supply and return hoses 2 Connect the Heat Exchangers to the appropriate electrical source 3 Cross connect valve 5 may be open or closed 4 Close valve 4 and valve 6 Run the machine NOTICE Only start the pumps when the Heat Exchangers are connected Starting the pumps when the Heat Exchangers are not connected will cause excess system pressure which m...

Page 97: ...ghi_tx001162gb fm 97 E 3000 Accessories wc_gr008560 a b LR RR RS LS HX 50 HX 50 ...

Page 98: ... Heat Exchanger to the appropriate electrical source NOTICE Cross connect valve 5 may be open or closed If closed do not turn on the right pump 3 Close valve 4 and valve 6 Run the machine NOTICE Only start the pump when the Heat Exchanger is connected Starting the pump when the Heat Exchanger is not connected will cause excess system pressure which may damage the pump 1 Start the E 3000 left pump ...

Page 99: ...ghi_tx001162gb fm 99 E 3000 Accessories wc_gr008561 a LR LS HX 50 ...

Page 100: ... Connect Heat Exchanger c to 2 1 adapter y Connect the SPP 1 Position the SPP near the machine 2 Connect Heat Exchanger c to the SPP d 3 Connect hose e to the supply port of the SPP and to valve 1 of the machine 4 Open valve 1 Complete the installation 1 Insulate the supply and return hoses 2 Connect the Heat Exchangers to the appropriate electrical source 3 Connect the SPP power cord to the APP 4...

Page 101: ...ghi_tx001162gb fm 101 E 3000 Accessories wc_gr008580 SPP HX 100 HX 100 HX 100 d e a b c LR RR y LS RS APP 2 1 ...

Page 102: ...lumbing rack RR Complete the installation 1 Insulate the supply and return hoses 2 Connect the Heat Exchangers to the appropriate electrical source 3 Open cross connect valve 5 4 Close valve 4 and valve 6 Run the machine NOTICE Only start the pumps when the Heat Exchangers are connected Starting the pumps when the Heat Exchangers are not connected will cause excess system pressure which may damage...

Page 103: ...ghi_tx001162gb fm 103 E 3000 Accessories wc_gr008582 HX 100 HX 100 a b LR RR LS RS ...

Page 104: ...t the Heat Exchanger to the appropriate electrical source NOTICE Cross connect valve 5 may be open or closed If closed do not turn on the right pump 3 Close valve 4 and valve 6 Run the machine NOTICE Only start the pump when the Heat Exchanger is connected Starting the pump when the Heat Exchanger is not connected will cause excess system pressure which may damage the pump 1 Start the E 3000 left ...

Page 105: ...ghi_tx001162gb fm 105 E 3000 Accessories wc_gr008583 HX 100 a LR LS ...

Page 106: ...onnect the 2 1 adapter c to both outputs of the DPP d 3 Connect hose e to the supply port of the DPP and to valve 1 of the machine 4 Open valve 1 Complete the installation 1 Insulate the supply and return hoses 2 Connect the Heat Exchangers to the appropriate electrical source 3 Connect the DPP power cord to the APP 4 Open cross connect valve 5 5 Close valve 4 and valve 6 Run the machine NOTICE On...

Page 107: ...ghi_tx001162gb fm 107 E 3000 Accessories wc_gr008584 APP c e d DPP a b LR LS RR RS 2 1 HX 200 HX 200 ...

Page 108: ...e Heat Exchangers to the appropriate electrical source 3 Connect the DPP power cord to the APP 4 Open cross connect valve 5 5 Close valve 4 and valve 6 Run the machine NOTICE Only turn on the pumps when the Heat Exchangers are connected Turning on the pumps when the Heat Exchangers are not connected will cause excess system pressure which may damage the pumps 1 Start the E 3000 and operate it with...

Page 109: ...ure test gauge General hand tools Mandates Adjustments must be made so that the machine conforms to the requirements of local state and federal codes and authorities Adjustments shall be made at the job site This procedure continues on the next page Head Firing rate L hr gph Nozzle size Fuel pressure bar psi Air band setting Air shutter F220 10 4 2 75 2 25 80 B 10 3 150 0 6 5 Fuel Blend Guide Lowe...

Page 110: ...See topic Setting Checking the Electrodes 3 Check the burner nozzle See topic Replacing the Burner Nozzle 4 Check set the Z distance See topic Setting the Z Distance 5 Set the air settings See topic Adjusting the Air Settings 6 Start the machine and the burner 7 Check set the fuel pressure See topic Adjusting the Fuel Pressure 8 Conduct a smoke spot test Follow the smoke spot tester manufacturer s...

Page 111: ...eneral guidelines below Use the access hole in the exhaust stack Take several samples as the heater warms Take the final sample just before the heater reaches 71 C 160 F 10 Re adjust the air setting s if necessary until the smoke spot test and combustion analysis are within the following parameters O2 content 4 6 Smoke spot 1 or less Result The burner has now been set up ...

Page 112: ...t the power supplies 2 Remove the copper fuel line a between the fuel pump and the burner housing 3 Remove the spline nut b that is seated against the escutcheon plate 4 Remove screws c and open igniter cover 5 Disconnect the wiring e to the nozzle electrode assembly 6 Maneuver the nozzle electrode assembly d up and out of the burner This procedure continues on the next page wc_gr008581 c wc_gr008...

Page 113: ...t the electrodes 8 Reconnect the preheater wiring 9 Reinstall the nozzle assembly into the burner Result The electrodes have now been checked adjusted Ref Description Gap distance h Electrode tip to electrode tip 5 32 in 4 mm i Nozzle center to electrode tip 5 16 in 7 5 mm j Nozzle end to electrode tip end 1 16 in 1 5 mm ...

Page 114: ... power supplies 2 Remove the copper fuel line a between the fuel pump and the burner housing 3 Remove the spline nut b that is seated against the escutcheon plate 4 Remove screws c and open igniter cover 5 Disconnect the wiring e to the nozzle electrode assembly 6 Maneuver the nozzle electrode assembly d up and out of the burner This procedure continues on the next page wc_gr008581 c wc_gr008596 e...

Page 115: ...ew the burner nozzle f from the burner tube 8 Install a new burner nozzle Note Do not use thread sealant on the threads of the nozzle 9 Reconnect the preheater wiring 10 Reinstall the nozzle electrode assembly into the burner Result The burner nozzle has now been replaced wc_gr008598 f ...

Page 116: ...om the machine 2 Loosen the knurled nut b 3 Loosen the position locking screw e 4 Set the Z distance by using the T501 gauge or by measuring as follows Beckett T501 gauge Using the Beckett T501 gauge a Position the gauge into the flame retention head as shown b Slide the nozzle assembly so that the front face of the burner nozzle touches the T501 gauge c Tighten the position locking screw This pro...

Page 117: ...nozzle assembly until the distance between the front face of the burner nozzle and the end of the flame retention head measures 1 5 8 inches 41 mm This is the Z distance c Tighten the position locking screw e After setting the Z distance complete the procedure 5 Tighten the knurled nut b 6 Mark x the escutcheon plate for later reference The procedure to set the Z distance is now complete x ...

Page 118: ...ate air settings increases efficiency and lowers stack temperature but may cause soot build up rich mixture Procedure Follow the procedure below to adjust the air settings 1 Initial setting of the air damper should be performed with the machine shut down 2 Loosen the air band locking screw a and the air shutter locking screw b 3 Using the band position pointer c to determine position move the air ...

Page 119: ...e the bleeder valve a from the fuel pump 3 Insert the gauge in place of the bleeder valve 4 If your machine has a generator start it 5 Move the burner ON OFF switch to ON The burner will go through a pre purge cycle Monitor and make adjustments during the pre purge cycle 6 Turn the adjusting screw b clockwise to increase fuel pressure counterclockwise to decrease fuel pressure Result The fuel pres...

Page 120: ...ou have proper certification or licensing required by the locality state or province in which the machine is being installed to connect natural gas or LP E 3000 NG LP Air damper setting 3 8 4 0 Combustion head setting 5 0 5 0 Gas manifold pressure in w c 3 1 4 5 Orifice mm 2 2 2 2 Diaphragm C6 C3 ...

Page 121: ...achine is being installed to connect natural gas or LP Restrictions The supply gas regulator a shall not be installed inside the machine enclosure Use only industry approved hose piping to connect the gas supply to the machine WARNING Explosion hazard Vented gas from the regulator accumulating within the machine enclosure poses an explosion hazard if ignited f Do not install the supply gas regulat...

Page 122: ...all be made at the job site When to adjust Adjust the burner Before operating the machine at elevations 305 m 1 000 ft above or below the location of where the last adjustments were made Before starting at a new job site After any burner maintenance or repair has been performed If burner performance is in question Procedure Follow the procedure below to set up the burner 1 Shut down the machine 2 ...

Page 123: ... before the heater reaches 71 C 160 F 10 Analyze the combustion Follow the combustion analyzer manufacturer s instructions and the general guidelines below Use the access hole in the exhaust outlet Take several samples as the heater warms Take the final sample just before the heater reaches 71 C 160 F 11 Re adjust the air setting s if necessary until the smoke spot test and combustion analysis are...

Page 124: ...rm the procedure below to remove the combustion head 1 Open the access door and locate the burner 2 Remove the burner assembly cover a 3 Remove nut c and open the burner 4 Make note of the position of the combustion head then remove screw d 5 Disconnect the wire e This procedure continues on the next page wc_gr008960 c wc_gr008977 a wc_gr008961 e d ...

Page 125: ...ion head 1 Install the combustion head into the burner Adjust the combustion per topic Adjusting the Combustion Head 2 Reconnect the wire to the ignition electrode 3 Close the burner and install nut c 4 Install the burner assembly cover a Result The procedure to remove and install the combustion head is now complete wc_gr008962 f wc_gr008963 f wc_gr008960 c wc_gr008977 a ...

Page 126: ...low it to cool 2 Remove the combustion head assembly See topic Removing and Installing the Combustion Head 3 Clean the combustion head 4 Adjust the ionization probe a so that it is positioned from the mixing plate as shown 5 Adjust the electrode b so that it is positioned from the mixing plate as shown Result Both the ionization probe and the electrode have now been adjusted Reinstall the combusti...

Page 127: ...m 1 Shut down the machine and allow it to cool 2 Remove the combustion head assembly f See topic Removing and Installing the Combustion Head 3 Loosen the clamp screw and remove the ionization probe a and the ignition electrode b 4 Remove the two screws c and remove the gas diffuser d 5 6 Remove the diphragm e from the elbow Install a new diaphragm Note There is a seal g inside the elbow it may be ...

Page 128: ...etting depends on environmental conditions at the job site 1 Shut down the machine and allow it to cool 2 Remove the burner cover 3 Loosen the two screws a that secure the air adjustment plate b 4 Rotate the air adjustment plate so that the proper number on the air adjustment plate lines up with the setting indicator c See topic Factory Settings 5 Once the air adjustment plate is set tighten the t...

Page 129: ...ss door and locate the burner 2 Remove the burner assembly cover a 3 Remove nut c and open the burner 4 Loosen screw d 5 Move the elbow e so that the edge of the air tube f coincides with the set point number 5 6 Tighten screw d 7 Close the burner and reinstall nut c 8 Reinstall the burner cover Result The combustion head has now been adjusted wc_gr008960 c wc_gr008977 a wc_gr008968 d wc_gr008498 ...

Page 130: ...Remove the plug a from the tee fitting 4 Install a nipple b into the tee fitting 5 Connect the hose of the manometer c to the nipple 6 Open the supply gas shutoff valve This procedure continues on the next page WARNING Explosion and fire hazard When combined with air the gas used for this burner is explosive Explosions can cause severe injury or death f Close the supply gas shutoff valve before co...

Page 131: ...r See section Technical Data for the correct pressure Adjust the supply gas pressure as needed 8 After the supply gas pressure has been set turn off the supply gas 9 Remove the manometer and the nipple 10 Re install the plug 11 Perform a leak test at the plug Result The supply gas pressure has now been checked and adjusted ...

Page 132: ... the OFF position 2 Locate the pressure test port c 3 Insert a small screwdriver into the pressure test port and back off the needle valve two revolutions 4 Connect the hose of the manometer d to the pressure test port 5 Turn the control knob to the ON position 6 Start the machine 7 With the burner firing check the pressure reading on the manometer See section Technical Data for the correct pressu...

Page 133: ...r gas pressure clockwise to increase pressure counterclockwise to decrease pressure Once the burner gas pressure is set 3 Reinstall the cap 4 Shut down the machine 5 Remove the manometer tube from the pressure test port 6 Tighten the needle valve NOTICE Do not overtighten the needle valve Damage to the needle valve will occur 7 Perform a leak test at the pressure test port Result The burner gas pr...

Page 134: ...aily 2 Week Yearly 50 1200 Inspect hose couplings 3 Clean quick connect couplings 3 Inspect hoses and connectors 3 Inspect electrical cords connections Check HTF level Fill if necessary 3 Check adjust burner air setting Check adjust fuel pressure Check adjust electrodes Replace burner nozzle Clean HTF strainer Replace fuel filter Lubricate hose reel chain Lubricate hose reel bearings Clean turbula...

Page 135: ...T handle clockwise Pump motor and hydronic heater 1 Inspect the pumps and motor assemblies and associated plumbing for leaks and or damage 2 Inspect hydronic heater and associated plumbing for leaks and or damage 3 Repair replace any damaged components 4 Repair any leaks Fuel System Burner 1 Inspect all fuel hoses and connections for leaks and or damage 2 Inspect the fuel filter and associated fue...

Page 136: ...rtion of the hose and clamp locking pliers on either side of the damaged portion 3 Cut away the damaged portion of the hose a using a utility knife or similar tool 4 Install a ferrule b on each end of the freshly cut hose 5 Insert a nipple c into one of the ferrules NOTICE Do not use petroleum to lubricate the nipple If lubrication is needed use HTF 6 Insert the free end of the nipple into the sec...

Page 137: ... fm 137 E 3000 Maintenance Continued from the previous page 7 Use a Wacker Neuson brand hose crimper e to crimp both ferrules 8 Rotate the hose 90 degrees and crimp both ferrules again The procedure is now complete ...

Page 138: ...on the following items for corrosion wear or damage Repair or replace as necessary This procedure continues on the next page WARNING Electric shock hazard High voltage exists at various locations in the machine High voltage can cause severe injury or death f Disconnect the power supplies before inspecting the electrical systems Item Reference Photo Control panel f Open the con trol panel Pump moto...

Page 139: ...E 3000 Maintenance Continued from the previous page Item Reference Photo Hose reel rewind motor d Light e Trailer f Lights f f Wiring harness g f Brake h Generator i if applicable Low level shut down device j Thermocouple k ...

Page 140: ...TF reservoir differs slightly from that when a low level fault is encountered If your machine has experienced a low level fault see topic Resetting a Low HTF Fault Procedure Follow the procedure below to fill the HTF reservoir 1 Move the burner switch to the OFF position 2 Move both pump switches to the OFF position 3 Clean the fill hose 4 Power up the machine 5 Remove the locking pin then open va...

Page 141: ...l is between the minimum and maximum marks on the sightglass NOTICE Do not overfill the HTF reservoir Doing so may damage the machine 9 Move valve 3 to the normal position 10 Remove the fill hose from the HTF container Allow any HTF within the hose to drip back into the container Cap the hose if a cap is included 11 Move the fill hose to its storage location under the hose reel 12 Open valve 2 and...

Page 142: ... environmental protection laws 1 Loosen but do not remove the top screw a Note There is a second screw b under the canister c Hold this screw while loosening the screw a 2 Tap on screw a with a hammer to release the gasket seal 3 Remove the canister c by removing screw a support the canister while doing so 4 Dispose of the HTF that remains in the canister 5 Remove the gasket d from the canister Re...

Page 143: ...replace it if it is damaged 2 To ensure strainer gasket f placement install the canister b over the strainer basket c 3 Install the gasket d to the canister 4 Install the strainer housing including strainer basket c into the machine using the screw a and screw b Result The HTF strainer is now clean and ready for operation ...

Page 144: ... cap c 4 Hold the filter housing g and lightly tap the bolt b with a hammer to break the seal between the gasket e and the housing g 5 Remove the bolt b and gasket d 6 Remove the filter housing cap c and gasket e 7 Pull the fuel filter element f out of the housing Installation Perform the procedure below to install the new fuel filter 1 Remove any remaining gasket material from the filter housing ...

Page 145: ... Perform the procedure below to lubricate the hose reel system 1 Disconnect electric power from the machine 2 Apply low temperature bearing grease with several pumps from a grease gun to each bearing a 3 Lightly apply a low temperature lubricating oil to the chain b Result The hose reel system has now been lubricated wc_gr007823 b ...

Page 146: ...pen with the door carefully remove it from where it is caught on the bolts c Inspect all panels for damaged insulation Replace all damaged panels 4 Locate the turbulators housed in the burner tubes 5 Remove the turbulators d by pulling the turbulator tab Replace any turbulator that is badly eroded 6 Clean each burner tube with a bottle brush This procedure continues on the next page WARNING Burn h...

Page 147: ...previous page 7 Vacuum out each burner tube 8 Remove the exhaust stack e both inner and outer panels 9 Vacuum out the exhaust ducting f and the heater 10 Reinstall the exhaust stack 11 Reassemble the machine Result The procedure is now complete f e wc_gr008604 ...

Page 148: ...sible on the black painted surface NOTICE If any of these symptoms exist investigate and repair the source Replace the rope gasket Follow the procedure below to replace the rope gasket 1 Remove the nuts b that secure the flue box door and remove the door 2 Remove the old gasket c and replace with a new one Note You may need to use a tool such as a screwdriver to remove the gasket The procedure is ...

Page 149: ... a at the quick connects 3 Remove the burner controller b to expose the wiring Label all the wires to assist in reconnecting 4 Disconnect all wires coming from the snap switch cable c at the burner controller 5 Disconnect all wires coming from the burner cable d 6 Remove the screws that secure the burner to the machine and maneuver the burner from the machine Result The procedure to remove the bur...

Page 150: ...nstall the burner 1 Position the burner inside the machine and secure it to the hydronic heater 2 Reconnect the wiring from the snap switch cable c and burner cable d to the burner controller 3 Mount the burner controller b to the burner 4 Connect the fuel lines a at the quick connects Result The procedure to install the burner is now complete wc_gr008595 c d b ...

Page 151: ...storage 1 Fill fuel tank with stabilized fuel and operate the burner for at least fifteen minutes to ensure circulation through entire fuel system Any brand of fuel stabilizer is acceptable 2 Allow heater to cool sufficiently Cover the chimney and the burner with plastic wrap or other waterproof material This will prevent corrosive moisture build up and blockages caused by animal nests 3 Shut and ...

Page 152: ...e genset is to be idle for more than 120 days 1 Change the engine oil 2 Place a tag on the genset designating engine oil viscosity 3 Disconnect the battery 4 Plug the exhaust tail pipe to keep out dirt moisture bugs etc 5 Clean the genset When returning the genset back into service 1 Reconnect the battery 2 Check the oil tag and change the engine oil if the oil viscosity is not appropriate for the...

Page 153: ...ll outside surfaces Heater and burner Remove protective coverings from chimney and burner Remove any carbon buildup from the heater and burner assemblies Replace the burner nozzle Verify burner electrode position Controls and wiring Inspect all wires for damage corrosion or wear Replace damaged wiring Inspect all electrical components for damage corrosion or wear Replace damaged electrical compone...

Page 154: ... to improve cold weather starting Precautions Observe the following precautions to prevent serious damage to the electrical system Do not disconnect the battery while the machine is running Do not attempt to run the machine without a battery Do not attempt to jump start the machine In the event that the machine has a discharged battery either replace the battery with a fully charged battery or cha...

Page 155: ... oil level 3 Check the engine coolant level 3 Clean and check battery 3 Clean spark arrestor 3 Change engine oil and oil filter 3 Replace engine air filter ele ment 3 Replace engine fuel filter Flush coolant system Replace coolant system pressure cap 3 Replace engine V belt Replace coolant hoses and thermostat Adjust engine valve lash Service fuel injectors Check generator bearings drive belt belt...

Page 156: ...e 4 Remove the dipstick plug and check the oil on the dipstick Adding oil NOTICE Too much oil can cause high oil consumption Too little oil can cause severe engine damage Add oil when the oil level approaches the ADD mark on the dipstick plug 1 Add oil through the fill opening until the oil level reaches the FULL mark on the dipstick plug 2 Reinstall the dipstick plug into the engine fully WARNING...

Page 157: ...iquid which drains off Dispose of this liquid in accordance with local environmental protection laws 1 Operate the genset until warm then stop the engine 2 Pull the oil dipstick plug out approximately 5 cm 2 in to allow the oil to drain faster 3 Remove the front and bottom access covers 4 Position the drain hose a into a container 5 Open the drain valve b and drain the used oil Dispose of used oil...

Page 158: ...l filter an additional 180 270 3 Refill the engine with 1 7 qt 1 9 liters of oil 4 Reinstall the access covers 5 Start the genset and allow it to run for a 1 3 minutes 6 Check the oil level Add oil as needed Result The engine oil and oil filter have now been changed wc_gr008035 c WARNING Most used oil contains small amounts of materials that can cause cancer and other health problems if inhaled in...

Page 159: ... 1 Check the engine coolant level through the opening a in the panel When cold the coolant level should be at the COLD mark on the recovery tank b 2 Fill the recovery tank when the engine is cold to the COLD mark on the recovery tank WARNING Personal injury hazard Contact with moving parts and hot exhaust can cause severe injury f Do not run the genset with the access covers removed wc_gr008033 b ...

Page 160: ...ry 2 Remove the front access cover a 3 Remove the wing nuts b bracket c filter housing d and the filter element e Installing 1 Perform the procedure below to install the air filter element 2 Install the new air filter element using the filter housing bracket and wing nuts Tighten wing nuts hand tight 3 Reinstall the front access cover 4 Reconnect the battery Result The air filter element has now b...

Page 161: ... not to spill fuel 5 Remove the filter mounting nut d and two filter bracket mounting screws e 6 Remove the filter bracket f and filter g Dispose of the filter according to state and local regulations Installation Perform the procedure below to install the fuel filter 1 Secure the filter bracket f loosely to the new filter g Place the filter bracket and new filter in the generator This procedure c...

Page 162: ...d and tighten one flat past seating 3 Tighten the filter mounting nut d and filter bracket mounting screws e 4 Reinstall the access cover using the flare nuts Prepare the machine Prepare the machine for operation 1 Reconnect the battery 2 Open the fuel supply valve 3 Replace any covers guards or access panels 4 Prime the fuel system Hold the control switch to the STOP PRIME position for at least o...

Page 163: ...pressure which is essential for best engine cooling Note In the interests of environmental protection place a plastic sheet and a container under the machine to collect any liquid which drains off Dispose of this liquid in accordance with local environmental protection laws Draining Perform the procedure below to drain the coolant 1 Disconnect the battery 2 Remove the access cover The fill hose as...

Page 164: ...n cock 2 Fill the cooling system with coolant through the fill opening using a funnel Note Using a funnel will prevent coolant from entering the vent hose y If coolant enters the vent hose it may block escaping air as the system fills If the vent hose is blocked the system will seem full when in fact it is not If the vent hose does become blocked a Pinch closed the overflow hose z b Blow the vent ...

Page 165: ...r Pressing Stop again will stop the blinking The two digit codes consist of 1 2 3 4 or 5 blinks a brief pause 1 to 9 blinks and then a long pause The code then repeats For example shut down code 36 appears as blink blink blink pause blink blink blink blink blink blink long pause repeat Four blinks indicates that engine cranking exceeded the preset time without the engine starting The preset time i...

Page 166: ...ry 3 Prime the engine fuel system by holding the control switch at Stop for one minute 4 Replace engine air filter 5 Replace the fuel filter 12 Over voltage fault The controller is not able to regulate to rated voltage See authorized Cummins Onan dealer 13 Under voltage fault The controller is not able to regulate to rated voltage Turn off the line circuit breaker on the console If the genset now ...

Page 167: ...lace the engine oil with oil of the proper viscosity for the ambient temperature 35 Control card fault Microprocessor EEPROM error during self test See authorized Cummins Onan dealer 36 Engine stopped fault The genset stopped without a command from the controller 1 Check fuel level refill fuel tank 2 Check for and repair fuel leaks Air in the fuel supply can disrupt frequency Prime the engine fuel...

Page 168: ...68gb fm 168 Genset Maintenance Onan Genset 57 Over prime fault Prime mode exceeded 3 minutes 1 Check control switch Remove anything that may be holding it in the Prime position Code Fault Type Corrective Action ...

Page 169: ...t the job site The soil conditions are not as expected Re evaluate thawing plan based on job site condi tions Pump will not start There is no power Verify that the breaker switch is ON Verify that the HTF level is within range and low level cutoff control is reset low level indicator light must be OFF The HTF temperature is below 26 C 15 F Warm the HTF and hoses before starting machine see topic P...

Page 170: ...is not fully open Verify that the suction valve is fully open The HTF temperature is below 26 C 15 F Warm the HTF and hoses before starting machine see topic Preheating the HTF in this manual The strainer basket is clogged Clean the strainer basket see topic Cleaning the HTF Strainer Problem Symptom Reason Remedy ...

Page 171: ... The burner nozzle is dam aged or worn Replace the burner nozzle The electrodes are defec tive Replace the electrodes The cadmium cell is mal functioning Replace the cadmium cell The burner primary control is malfunctioning Replace the burner primary control The burner starts and the flame ignites but the unit locks out The fuel pressure is set incorrectly Adjust the fuel pressure The burner nozzl...

Page 172: ...rt when the temperature con troller calls for heat There is low gas pressure Adjust the gas pressure The 24V switching relay is faulty Replace the 24V relay The burner switch is OFF Turn the burner switch ON The circuit breaker is tripped Reset the circuit breaker Terminals on the control module are bent or loose Repair or replace the con trol module The motor is faulty Repair or replace the motor...

Page 173: ...ength m ft 914 3 000 HTF capacity L gal 435 115 HTF pump L hr gph 2 X 1 003 2 X 265 Burner nozzle gph X deg 2 25 X 80 B Fuel pressure bar psi 10 34 150 Fuel input type Diesel Heat ouput kW hr BTU hr 113 385 000 Heater efficiency 83 Run time up to hr 140 Hose pressure bar psi 6 2 7 5 90 110 Standard thaw capacity m2 ft2 279 558 3 000 6 000 Accelerated thaw capacity m2 ft2 558 6 000 Standard cure ca...

Page 174: ... 3000 GAWR Gross Axle Weight Rating kg lb 1 588 3 500 2 359 5 200 Wheel diameter mm in 356 14 381 15 Tire code 225 75R14 215 75R15 Tire pressure kPa psi 345 50 448 65 Lug nut torque Nm ft lbs 150 110 GVWR Gross Vehicle Weight Rating kg lb 3 499 7 715 3 895 8 582 Brake type Electric Maximum towing speed km h MPH 72 45 wc_gr008852 231 91 459 181 238 94 ...

Page 175: ...and MI 48674 USA Customer Information Number 800 258 2436 SDSQuestion dow com EMERGENCY TELEPHONE NUMBER 24 Hour Emergency Contact 989 636 4400 Local Emergency Contact 989 636 4400 2 Hazards Identification Emergency Overview Color Yellow to green Physical State Liquid Odor Characteristic Hazards of product No significant immediate hazards for emergency response are known OSHA Hazard Communication ...

Page 176: ...efer to Section 8 for specific personal protective equipment 5 Fire Fighting Measures Extinguishing Media To extinguish combustible residues of this product use water fog carbon dioxide dry chemical or foam Fire Fighting Procedures Keep people away Isolate fire and deny unnecessary entry Use water spray to cool fire exposed containers and fire affected zone until fire is out and danger of reigniti...

Page 177: ...ferred glove barrier materials include Butyl rubber Natural rubber latex Neoprene Nitrile butadiene rubber nitrile or NBR Polyethylene Ethyl vinyl alcohol laminate EVAL Polyvinyl alcohol PVA Polyvinyl chloride PVC or vinyl NOTICE The selection of a specific glove for a particular application and duration of use in a workplace should also take into account all relevant workplace factors such as but...

Page 178: ...on Temperature No test data available Partition coefficient n octanol water log Pow No data available for this product Evaporation Rate Butyl Acetate 1 0 5 Estimated Kinematic Viscosity 6 3 cSt Literature 10 Stability and Reactivity Stability Instability Thermally stable at recommended temperatures and pressures Conditions to Avoid Some components of this product can decompose at elevated temperat...

Page 179: ...al Information ENVIRONMENTAL FATE Movement Partitioning For the major component s Bioconcentration potential is low BCF less than 100 or log Pow less than 3 Potential for mobility in soil is very high Koc between 0 and 50 Persistence and Degradability For the major component s Material is readily biodegradable Passes OECD test s for ready biodegradability ECOTOXICITY For the major component s Mate...

Page 180: ... Reactive Hazard No Sudden Release of Pressure Hazard No Superfund Amendments and Reauthorization Act of 1986 Title III Emergency Planning and Community Right to Know Act of 1986 Section 313 To the best of our knowledge this product does not contain chemicals at levels which require reporting under this statute Pennsylvania Worker and Community Right To Know Act Pennsylvania Hazardous Substances L...

Page 181: ...nvironmental Exposure Level HAZ_DES Hazard Designation Action Level A value set by OSHA that is lower than the PEL which will trigger the need for activities such as exposure monitoring and medical surveillance if exceeded The Dow Chemical Company urges each customer or recipient of this M SDS to study it carefully and consult appropriate expertise as necessary or appropriate to become aware of an...

Page 182: ...MSDS Dowfrost HD 50 ...

Page 183: ...3 TAP TWICE THE VALUE OF THE GREEN NUMBER SHOULD READ ZERO X 2 PRESS HOLD UNTIL THE NORMAL DISPLAY APPEARS 4 5 PRESS AND HOLD RELEASE WHEN P IS DISPLAYED 1 PRESS AND HOLD RELEASE WHEN LoC IS DISPLAYED 8 TAP REPEATEDLY UNTIL THE VALUE CORRESPONDS TO THE GUIDE BELOW 7 TAP ONCE THE GREEN NUMBERS WILL BEGIN FLASHING 6 TAP REPEATEDLY UNTIL HYS IS DISPLAYED PRESS HOLD UNTIL THE NORMAL DISPLAY APPEARS 9 ...

Page 184: ...heat 50 Arctic Bear XHD HD models 50 FUJI PXR 4 LOW TEMPERATURE LIMIT ADJUSTING 2 TAP ONCE THE GREEN NUMBER WILL BEGIN FLASHING X 1 3 TAP TWICE THE VALUE OF THE GREEN NUMBER SHOULD READ ZERO X 2 PRESS HOLD UNTIL THE NORMAL DISPLAY APPEARS 4 SEL 1 PRESS AND HOLD RELEASE WHEN LoC IS DISPLAYED PRESS HOLD UNTIL THE NORMAL DISPLAY APPEARS 9 C1 C2 AL1 AL3 AL2 PRESS HOLD UNTIL THE NORMAL DISPLAY APPEARS ...

Page 185: ...2200 S3000 E3000 Pureheat 180 Arctic Bear XHD HD models 210 FUJI PXR 4 HIGH TEMPERATURE LIMIT ADJUSTING 2 TAP ONCE THE GREEN NUMBER WILL BEGIN FLASHING X 1 3 TAP TWICE THE VALUE OF THE GREEN NUMBER SHOULD READ ZERO X 2 PRESS HOLD UNTIL THE NORMAL DISPLAY APPEARS 4 1 PRESS AND HOLD RELEASE WHEN LoC IS DISPLAYED PRESS HOLD UNTIL THE NORMAL DISPLAY APPEARS 9 PRESS HOLD UNTIL THE NORMAL DISPLAY APPEAR...

Page 186: ...wc_tx001673gb fm 186 Fuji Temperature Controller ...

Page 187: ...gulation 49 CFR 575 requires trailer manufacturers to include certain tire information in the Owner s Manuals for the trailers they manufacture This regulation requires that the information be in the English language This chapter includes all the information required by Federal Regulation 49 CFR 575 ...

Page 188: ...forward half of the left road side of the unit This FHUWLILFDWLRQ 9 1 ODEHO ZLOO LQGLFDWH WKH WUDLOHU V URVV 9HKLFOH HLJKW 5DWLQJ 9 5 7KLV LV WKH PRVW ZHLJKW WKH IXOO loaded trailer can weigh It will also provide the Gross Axle Weight Rating GAWR This is the most a particular axle can weigh If there are multiple axles the GAWR of each axle will be provided If your trailer has a GVWR of 10 000 poun...

Page 189: ...LFOH HLJKW 5DWLQJ RI WKH WUDLOHU RQ RXU WUDLOHU V 9 1 HUWLILFDWLRQ ODEHO 3 Subtract the empty weight of your trailer from the GVWR stated on the VIN label That weight is the maximum available cargo capacity of the trailer and may not be safely exceeded 1 2 STEPS FOR DETERMINING CORRECT LOAD LIMIT TOW VEHICLE 1 RFDWH WKH VWDWHPHQW 7KH FRPELQHG ZHLJKW RI RFFXSDQWV DQG FDUJR VKRXOG QHYHU H FHHG OEV R...

Page 190: ...rim in a manner that encloses the rim flanges inside the air cavity of the tire Curb weight The weight of a motor vehicle with standard equipment including the maximum capacity of fuel oil and coolant and if so equipped air conditioning and additional weight optional engine Extra load tire A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard ...

Page 191: ...wheel supports the tire and attaches either integrally or separably to the wheel center member and upon which the tire is attached Non pneumatic spare tire assembly A non pneumatic tire assembly intended for temporary use in place of one of the pneumatic tires and rims that are fitted to a passenger car in compliance with the requirements of this standard Non pneumatic tire A mechanical device whi...

Page 192: ...formation label and on the Certification VIN tag Reinforced tire A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard tire Rim A metal support for a tire or a tire and tube assembly upon which the tire beads are seated Rim diameter This means the nominal diameter of the bead seat Rim size designation This means the rim diameter and width Rim ...

Page 193: ...l a mechanical device which attaches either integrally or separably to the non pneumatic tire and provides the connection between tire and the vehicle Wheel holding fixture The fixture used to hold the wheel and tire assembly securely during testing 1 4 TIRE SAFETY EVERYTHING RIDES ON IT The National Traffic Safety Administration NHTSA has published a brochure DOT HS 809 361 that discusses all asp...

Page 194: ...will also find this number on the vehicle information placard expressed in kilopascals kpa which is the metric measure used internationally Manufacturers of passenger vehicles and light trucks determine this number based on the vehicle s design load limit that is the greatest amount of weight a vehicle can safely carry and the vehicle s tire size The proper tire pressure for your vehicle is referr...

Page 195: ...any doubt about the correct size to choose consult with the tire dealer 1 5 6 TIRE TREAD The tire tread provides the gripping action and traction that prevent your vehicle from slipping or sliding especially when the road is wet or icy In general tires are not safe and should be replaced when the tread is worn down to 1 16 of an inch Tires have built in treadwear indicators that let you know when ...

Page 196: ...mber is the wheel or rim diameter in inches If you change your wheel size you will have to purchase new tires to match the new wheel diameter Next number This two or three digit number is the tire s load index It is a measurement of how much weight each tire can support You may find this information in your owner s manual If not contact a local tire dealer Note You may not find this information on...

Page 197: ...ufacturers also must indicate the materials in the tire which include steel nylon polyester and others Maximum Load Rating This number indicates the maximum load in kilograms and pounds that can be carried by the tire Maximum Permissible Inflation Pressure This number is the greatest amount of air pressure that should ever be put in the tire under normal driving conditions 1 5 9 2 UTQGS Informatio...

Page 198: ... as a single Load Range This information identifies the tire s load carrying capabilities and its inflation limits 1 6 TIRE SAFETY TIPS Preventing Tire Damage Slow down if you have to go over a pothole or other object in the road Do not run over curbs or other foreign objects in the roadway and try not to strike the curb when parking Tire Safety Checklist Check tire pressure regularly at least onc...

Page 199: ...Tire Safety Information ...

Page 200: ...wc_tx001952gb fm 200 Schematics E 3000 12 Schematics 12 1 Composite Schematic Machine with Oil Burner ...

Page 201: ...wc_tx001952gb fm 201 E 3000 Schematics 12 2 Composite Schematic Machine with Gas Burner ...

Page 202: ...rcuit breaker 1 GFCI 1 Ground Fault Circuit Interrupt 1 FU1 Fuse 1 HOSE REWIND Hose rewind ON OFF switch MTR Rewind motor RT right pump Left pump Burner motor FU2 Fuse 2 n a Rewind transformer n a n a To line 30 n a n a To line 29 RECT1 Rectifier Foot switch 1 SOL1 Solenoid 1 right clutch SOL2 Solenoid 2 left clutch SOL3 Solenoid 3 fuel K2 Relay coil K2 FOOT SWITCH SOL 2 GRN WHT SOL 3 K2 ...

Page 203: ...mally open contacts K1 K1 Relay normally closed contacts K1 PL1 Pilot light 1 Low level fault PL2 Pilot light 2 Burner fault DUPLEX Duplex receptacle HOUR METER Hour meter n a Ignition transformer T C type T Thermocouple Type T TEMP CONTROLLER Temp temperature controller n a Cab light CAB LIGHT Cab light ON OFF switch BURNER Burner ON OFF switch PUMP Pump ON OFF switch Symbol Ref Description K2 K2...

Page 204: ...ENTARY Low level shut down device momentary override ON OFF switch E STOP Emergency stop switch K4 Relay coil K4 K4 Relay normally closed contacts K4 K4 Relay normally open contacts K1 FU4 Fuse 4 FU5 Fuse 5 BURNER CONTROLLER Burner Controller Symbol Ref Description E STOP K4 K4 95 96 K4 JJN 50 FU4 FU5 JJN 50 C C A V BM IG L2 T T L1 ...

Page 205: ...wc_tx001952gb fm 205 E 3000 Schematics 12 4 Circulation System Circuit ...

Page 206: ...wc_tx001952gb fm 206 Schematics E 3000 12 5 Rewind System Circuit ...

Page 207: ...wc_tx001952gb fm 207 E 3000 Schematics 12 6 Gas Train Schematic ...

Page 208: ...wc_tx001952gb fm 208 Schematics E 3000 12 7 Generator ...

Page 209: ...slots on the trailer plug receptacle are each designated for specific components The designations are as follows Ref Designation Wire color a Battery 12V Black b Running lights Green c Left hand turn stop Red d Ground White e Electric brake Blue f Right hand turn stop Brown g Back up Yellow ...

Page 210: ... for specific components The designations are as follows Note The colors used on your vehicle s plug may vary from those used in the trailer junction box CHARGER wc_gr008478 B black R red G green W white Wire Colors Gr gray L blue Br brown BREAKAWAY SWITCH W W B B W W B G R R G W B R R R R B R B R G G Br B B B Br L L TRAILER TOW VEHICLE ...

Page 211: ..._tx001952gb fm 211 E 3000 Schematics 12 10 Trailer Lights and Brakes Wiring Diagram wc_gr008465 a1 a2 b1 c1 b2 c2 d1 k1 d2 k2 f e1 e2 g h1 j i1 h2 i2 R W L Br Br G a1 a2 b1 b2 c1 c2 d1 k1 k2 d2 f e1 e2 g ...

Page 212: ...e light amber b2 Left side miniature light amber c1 Right side fender light amber c2 Left side fender light amber d1 Right rear fender light red d2 Left rear fender light red e1 Right side stop and tail light e2 Left side stop and tail light f License plate light g 3 bulb combination light h1 Right front brake h2 Left front brake i1 Right rear brake i2 Left rear brake j To junction box ...

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Page 214: ...i zamiennych skontaktuj się z przedstawicielem firmy Wacker Neuson lub skorzystaj z witryny internetowej http wackerneuson com Důležité upozornění Pro informace o náhradních dílech prosím kontaktujte svého Wacker Neuson dealera nebo navštivte webové stránky http www wackerneuson com FONTOS A pótalkatrészekre vonatkozó információkért kérjük forduljon Wacker Neuson kereskedőjéhez vagy látogasson el ...

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