Wacker Neuson E3000 Operator'S Manual Download Page 136

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wc_tx001803gb.fm

136

Maintenance

E 3000

8.3

Repairing a Hose

Requirements

Hose nipple

Two hose ferrules

Hose crimping tool, Wacker Neuson part number 5000169002

Procedure

Follow the procedure below to repair a damaged hose.

1. Shut down the machine and allow the Heat Transfer Fluid (HTF) to cool.

2. Locate the damaged portion 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 second ferrule. Be sure to push each

end of each hose to the lip of the nipple.

This procedure continues on the next page.

Summary of Contents for E3000

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...

Page 3: ...y 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 p...

Page 4: ...afety 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 w...

Page 5: ...difications 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...

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

Page 7: ...ocations 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 T...

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 Opera...

Page 9: ...on 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 t...

Page 10: ...he 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...

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 seriou...

Page 12: ...manently 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...

Page 13: ...hine 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 mee...

Page 14: ...ne 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 f...

Page 15: ...f 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 machin...

Page 16: ...u 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 spe...

Page 17: ...e 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...

Page 18: ...ments 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 aw...

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...

Page 20: ...perly 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...

Page 21: ...n 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...

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: ...dditives 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...

Page 25: ...luid 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 furt...

Page 26: ...t 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 CAUTI...

Page 27: ...chine 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...

Page 28: ...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 fue...

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 L...

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 Con...

Page 31: ...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 th...

Page 32: ...amps 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 s...

Page 33: ...ing 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 mac...

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 opera...

Page 35: ...ic 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 Che...

Page 36: ...hine 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 t...

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 func...

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 ma...

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

Page 40: ...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...

Page 41: ...ations 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...

Page 42: ...l 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...

Page 43: ...ccessory 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 re...

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: ...F 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...

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...

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...

Page 48: ...fore 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...

Page 49: ...hine 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 powe...

Page 50: ...el 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 addit...

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 g...

Page 52: ...lose 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 damag...

Page 53: ...ing 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...

Page 54: ...e 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 ful...

Page 55: ...ith 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...

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 Insp...

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...

Page 58: ...tem 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 contr...

Page 59: ...utton 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 Rese...

Page 60: ...00 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...

Page 61: ...re 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...

Page 62: ...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...

Page 63: ...cation 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 periodical...

Page 64: ...t 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...

Page 65: ...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 T...

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 enga...

Page 67: ...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...

Page 68: ...FF 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 Packin...

Page 69: ...ity 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 WA...

Page 70: ...ccur 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...

Page 71: ...r 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 v...

Page 72: ...n 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 F...

Page 73: ...uit 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 P...

Page 74: ...sed 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 satisfi...

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 lo...

Page 76: ...ve 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 ye...

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

Page 78: ...wing 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 t...

Page 79: ...ine 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...

Page 80: ...l 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...

Page 81: ...ed 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 a...

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 femal...

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: ...002 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 Ret...

Page 85: ...ms 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 Th...

Page 86: ...ete 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 th...

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 H...

Page 88: ...ear 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...

Page 89: ...n 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 H...

Page 90: ...n 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...

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: ...ter 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...

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: ...o 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 retu...

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: ...ack 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...

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 s...

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 t...

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: ...umbing 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 valv...

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

Page 104: ...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 O...

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

Page 106: ...nnect 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 ret...

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: ...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 whe...

Page 109: ...re 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 jo...

Page 110: ...ee 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 Ad...

Page 111: ...neral 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...

Page 112: ...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 ignite...

Page 113: ...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 el...

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 cov...

Page 115: ...w 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...

Page 116: ...m 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...

Page 117: ...ozzle 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...

Page 118: ...te 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...

Page 119: ...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 p...

Page 120: ...u 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 Combust...

Page 121: ...chine 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...

Page 122: ...ll 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 startin...

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 Tak...

Page 124: ...m 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...

Page 125: ...on 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...

Page 126: ...ow 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...

Page 127: ...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 a...

Page 128: ...tting 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 Rota...

Page 129: ...s 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...

Page 130: ...emove 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...

Page 131: ...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...

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 p...

Page 133: ...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...

Page 134: ...ily 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...

Page 135: ...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 an...

Page 136: ...tion 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...

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...

Page 138: ...n 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 th...

Page 139: ...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 d...

Page 140: ...F 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...

Page 141: ...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...

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...

Page 143: ...eplace 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 str...

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 a...

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...

Page 146: ...en 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 R...

Page 147: ...revious 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 m...

Page 148: ...ible 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 nut...

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 con...

Page 150: ...stall 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 t...

Page 151: ...torage 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 hea...

Page 152: ...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...

Page 153: ...l 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 electro...

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 atte...

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 c...

Page 156: ...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 app...

Page 157: ...quid 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...

Page 158: ...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...

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 th...

Page 160: ...y 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 th...

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...

Page 162: ...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 fo...

Page 163: ...ressure 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 Disp...

Page 164: ...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...

Page 165: ...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 app...

Page 166: ...y 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...

Page 167: ...ace 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...

Page 168: ...8gb 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 Correcti...

Page 169: ...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...

Page 170: ...s 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 strai...

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 con...

Page 172: ...t 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 swi...

Page 173: ...ngth 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 11...

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 G...

Page 175: ...nd 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 Identifica...

Page 176: ...fer 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...

Page 177: ...erred 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...

Page 178: ...n 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 Literat...

Page 179: ...l 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...

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 bes...

Page 181: ...vironmental 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 sur...

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

Page 183: ...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...

Page 184: ...eat 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...

Page 185: ...200 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 SHO...

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

Page 187: ...ulation 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 E...

Page 188: ...orward 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 a...

Page 189: ...FOH 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 cap...

Page 190: ...im 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...

Page 191: ...heel 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 intend...

Page 192: ...ormation 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 fo...

Page 193: ...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...

Page 194: ...ill 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 determin...

Page 195: ...ny 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 espe...

Page 196: ...ber 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 lo...

Page 197: ...facturers 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 car...

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...

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: ...cuit 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...

Page 203: ...ally 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...

Page 204: ...NTARY 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 F...

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: ...lots 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 s...

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 whi...

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...

Page 212: ...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 tai...

Page 213: ......

Page 214: ...rveonderdelen Importante Para obter informa es sobre as pe as sobresselentes consulte o seu fornecedor da Wacker Neuson ou aceda ao site Web da Wacker Neuson em http www wackerneuson com Wa ne W celu...

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