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Owner’s Manual for Flameless Heat Cart

iii

Table of Contents

Section 1: Introduction and Safety

Introduction ..................................................................1

Read This Manual Thoroughly ....................................1

Safety Rules .................................................................1

How to Obtain Service .................................................1

General Hazards ...........................................................2

Explosion and Fire Hazards ........................................2

Towing Hazards ...........................................................3

Battery Hazards ............................................................3

Service Safety ..............................................................3

Section 2: General Information

Specifications................................................................5

Internal Component Locations ....................................6

External Component Locations ...................................7

Emissions Information ................................................8

Engine Oil Recommendations ....................................8

Selection of Viscosity ..................................................8

Coolant Recommendations ........................................8

Fuel System ..................................................................8

Hydraulic Oil .................................................................9

Cart Towing Guidelines ...............................................9

Parking Brake Use ......................................................9

Controller ....................................................................10

Monitoring, Diagnostic, and Protective Features .......10

Section 3: Operation

Theory of Operation ...................................................11

Before Starting Engine ..............................................11

Pre-Start Checklist ....................................................11

Engine Oil Level Check .............................................11

Hydraulic Oil Check ...................................................11
Engine Coolant Check ...............................................11

Ducting Guidelines ....................................................12

Engine and Heater Startup ........................................12

Adjusting Heater Output ...........................................13

AUTO Mode ..............................................................13
MANUAL Mode .........................................................13

Heater and Engine Shutdown ...................................14

Positive Air Shutdown (PAS) ....................................14

Testing the PAS ........................................................15
Resetting the PAS .....................................................15

Section 4: Maintenance

Maintenance ...............................................................17

Maintenance Tasks ....................................................17

Daily Walk Around Inspection ...................................17
Draining and Refilling the Oil .....................................17
Adding Coolant ..........................................................18

Maintenance Schedule ..............................................18

Engine Maintenance Schedule...................................19
Other Maintenance Checks........................................20

Battery Inspection ......................................................21

Battery Installation and Replacement ........................21

Other Maintenance Checks .......................................22

Short Term Storage ...................................................22

Return to Service .......................................................22

Section 5: Troubleshooting

General Troubleshooting Guide ................................23

Digital Controller Status Messages...........................26

Section 6: Installation Diagrams

Engine Harness (1 of 3) ..............................................27

Engine Harness (2 of 3) ..............................................28

Engine Harness (3 of 3) ..............................................29

Hydraulic System Schematic.....................................30

Hydraulic Heat System ...............................................31

Содержание MAC400HC

Страница 1: ...E THIS MANUAL FOR FUTURE REFERENCE MAC400FHC Flameless Heat Cart Owner s Manual MODEL NUMBER _________________________ SERIAL NUMBER _________________________ DATE PURCHASED ________________________ 004390 ...

Страница 2: ...ii Owner s Manual for Flameless Heat Cart 000393a WARNING CANCER AND REPRODUCTIVE HARM www P65Warnings ca gov ...

Страница 3: ... Checklist 11 Engine Oil Level Check 11 Hydraulic Oil Check 11 Engine Coolant Check 11 Ducting Guidelines 12 Engine and Heater Startup 12 Adjusting Heater Output 13 AUTO Mode 13 MANUAL Mode 13 Heater and Engine Shutdown 14 Positive Air Shutdown PAS 14 Testing the PAS 15 Resetting the PAS 15 Section 4 Maintenance Maintenance 17 Maintenance Tasks 17 Daily Walk Around Inspection 17 Draining and Refil...

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Страница 5: ...fixed to the unit are not all inclusive If using a procedure work method or operating technique that the manufacturer does not spe cifically recommend verify that it is safe for others and does not render the equipment unsafe Throughout this publication and on tags and decals affixed to the unit DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a part...

Страница 6: ...quipment or property damage Do not block air intake or restrict proper air flow Doing so could result in unsafe operation or damage to unit CAUTION 000240a Unit damage Do not stop engine before heating unit is cooled Doing so could result in unit damage CAUTION 000246 Equipment Damage The emergency stop switch is not to be used to power down the unit under normal operating circumstances Doing so w...

Страница 7: ...lure to do so could result in death serious injury or property or equipment damage 000364 WARNING Control loss Trailer must be securely coupled to the hitch An incorrectly coupled trailer could result in loss of control death or serious injury 000360 Personal injury Do not operate unit during transport Doing so could result in death serious injury or property damage 000231a WARNING 000137a WARNING...

Страница 8: ...4 Owner s Manual for Flameless Heat Cart Introduction and Safety This page intentionally left blank ...

Страница 9: ...05 mm Electrical 12V Engine Fuel Diesel Number 1 D Number 2 D Engine Fuel Capacity 55 gal 208 L Engine Oil Capacity 11 qt 10 4 L Engine Coolant Capacity 2 5 gal 9 5 L HTF Capacity 24 gal 90 8 L Engine Fuel Rate at 100 prime 3 2 gph 12 1 Lph Run Time 18 8 hr Temperature Rise 180 F 82 C Pump Hydraulic piston pump Fan 18 25 in 46 36 cm diameter backward inclined Hitch Type Pintle ring Tire Size 4 in ...

Страница 10: ...ilter L Engine oil dipstick C Hydraulic fluid breather separator M Diesel injection system D Hydraulic fluid fill N Fuel pump E Reservoir fluid level indicator P Fuel filters F Hydraulic fluid reservoir Q Engine oil filter G Hydraulic fluid filters R Engine oil cooler H Battery disconnect switch J Fluid drain oil fuel coolant 001918 001920 A B C D E F G H J K L M N P Q R ...

Страница 11: ...Components A Muffler I Ducting storage rear B Air intake cap J Diesel fuel fill C Tie down rings K Street side engine access D Tow hitch L Temperature beacon amber E Parking brake lever M Low fuel level beacon blue F Curb side engine access G Control panel H Fork lift pockets 004395 A C B D E F G H C L M I J K ...

Страница 12: ...0 antifreeze water mix which provides protection to approximately 58 F 50 C Coolant must be nitrite free and meet the perfor mance standards of ASTM D6210 NOTE Recommended coolant is ZEREX Nitrate Free Extended Life Antifreeze Coolant Test coolant yearly or every 1000 hours whichever comes first See the diesel engine manual for more infor mation Fuel System The engine is designed to use either Num...

Страница 13: ...ocked position The locking lever A holds the tow bar in place Do not operate the unit without the parking brake engaged Lift the locking lever up and slowly lower the tow bar to disengage the parking brake NOTE Do not attempt to move the unit with the parking brake engaged equipment damage may occur Applicable Standard Recommendation JIS Japanese Industrial Standard No 2 DIN Deutsche Industrie Nor...

Страница 14: ...tatus The controller will automatically stop the unit and display fault information if conditions occur outside of predetermined manufacturing parameters The controller can also display a variety of critical alerts diagnostics and recommendations The controller provides a variety of real time current operating condition data See the engine harness wiring diagrams for more information Button Positi...

Страница 15: ...ase and wipe it clean with a clean lint free cloth 2 Insert oil dipstick fully into oil dipstick tube and then remove slowly 3 Oil level must be between the FULL and ADD marks on the oil dipstick 4 Add oil if necessary to adjust the level After add ing or changing the oil run the engine for one min ute before checking the oil level Wait 10 minutes to allow the engine to cool and oil to fully drain...

Страница 16: ...een displays Start Engine WARNING Burn hazard Do not remove ducting until all air pressure has been emptied from hose duct Failure to do so could result in severe injury 000288 000108 WARNING Hot Surfaces When operating machine do not touch hot surfaces Keep machine away from combustibles during use Hot surfaces could result in severe burns or fire WARNING Crushing hazard Verify parking brake is p...

Страница 17: ... blowing from ducts the amber strobe light on top of the unit activates and the screen displays Heater On Press OFF to stop the heater Figure 3 5 Heater On Adjusting Heater Output Use the up and down arrows to adjust temperature selec tion to desired outlet temperature The options are 100 F 38 C 120 F 49 C 140 F 60 C and 160 F 71 C Monitor regularly and adjust as needed AUTO Mode In AUTO mode outp...

Страница 18: ...itive Air Shutdown PAS See Figure 3 10 This unit is equipped with a manually activated positive air shutdown PAS on the air intake If the atmosphere contains combustible propane or natural gas a positive air shutdown can be activated to prevent these gases from being drawn into the engine and ignit ing The PAS system stops the engine by closing an internal valve and obstructing intake air See Figu...

Страница 19: ...ve is closed by verifying that the reset knob is rotated completely clockwise If any resistance is felt or the valve does not close contact Generac Mobile Products Technical Support Resetting the PAS The emergency PAS system must be reset after each emergency event according to the steps below 1 Turn the control power switch to OFF O 2 Locate the PAS valve located inside the cabinet of the unit 3 ...

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Страница 21: ...he vents and on top of unit Inspect outer cover for significant damage beyond scuffs and small nicks Inspect for wire abrasion Inspect the fan belt for cracking fraying and stretching Verify the belt is properly seated in the pulley grooves Check coolant Check electrical connectors battery and ground points Look for loose or missing hardware Check all flexible rubber hoses for deterioration Check ...

Страница 22: ...ollowing is the manufacturer s recommended maintenance sched ule The maintenance items need to be performed more frequently if the unit is used in severe applications such as very high or very low ambient conditions or extremely dirty or dusty environments Use the unit hour meter or calendar time whichever occurs first from the previous maintenance interval to determine the next required maintenan...

Страница 23: ...cking Every Six Months Inspect wheel bearings Every 12 Months Replace coolant At 50 Operation Hours Break In Change engine oil and oil filter Change engine fuel filters At 250 Operation Hours Replace fuel filter element Clean water sedimenter element Clean electromagnetic pump filter At 500 Operation Hours Change engine oil and oil filter element Inspect engine accessory drive belts Inspect fuel s...

Страница 24: ...pply system Clean positive crankcase ventilation valve Inspect injection nozzle Change fuel filter element Clean water sedimenter element Clean electromagnetic pump filter After 1500 Operation Hours All hours based checks and maintenance should now be performed every 250 hours When servicing these items consult the equipment supplier NOTE All service and maintenance or repairs are recommended to b...

Страница 25: ...equired the battery must be replaced with one of equivalent size voltage and CCA cold crank amp capacity Minimum CCA for this unit is 950 Contact a GMP ASD for correct battery size A new battery must be filled with the proper electrolyte and be fully charge before installing Battery cables are connect to the unit at the factory Connect cables to battery posts as follows NOTE Turn the battery disco...

Страница 26: ...ra tion Store in a safe location do not position near or on top of any combustible materials observe any local state or national codes or regulations Store in a low moisture low dust area Disconnect the negative cable from the battery Return to Service Follow the guidelines below for engines and units that have not been operated for three to six months Conduct a thorough inspection of the unit bef...

Страница 27: ...tric start Discharged battery Replace battery See Battery Installation and Replacement Battery terminal is disconnected loose or corroded Replace corroded part s and tighten securely Starter ground terminal is disconnected loose or corroded Excessive engine oil viscosity Change with oil of correct viscosity See Draining and Refilling the Oil Starter or electrical system failure Contact a GMP ASD E...

Страница 28: ... is clogged with dust Clean with soft brush Subtank cap is not tightened Tighten or replace sub tank cap Fouled coolant Clean inside of radiator and change coolant Oil in coolant Contact a GMP ASD Thermostat failure Change thermostat Oil pressure does not rise Incorrect engine oil viscosity Change with oil of correct viscosity See Draining and Refilling the Oil Insufficient engine oil Replenish en...

Страница 29: ...on Blower fan operating incorrectly Remove ducting check blower fan opera tion No low heat condition Incorrect heater setting target tempera ture too low Adjust heater output See Adjusting Heater Output Access doors are open Close all access doors Insufficient HTF hydraulic oil level Check level on tank sight glass adjust as needed Inspect HTF hoses for leaks or loose fittings Check fluid for foam...

Страница 30: ... load reduced to 50 Fuel level 12 Fuel level notification appears on screen Open heat circuit and close scroll fan circuit Drop engine to idle Fuel level 8 Fuel level notification appears on screen Engine shuts down Check heater settings or connections then press Reset on the Machine Overview IFM controller detected a short or break in a sender Heater is cooling down Please wait IFM controller det...

Страница 31: ...Owner s Manual for Flameless Heat Cart 27 Installation Diagrams Section 6 Installation Diagrams Engine Harness 1 of 3 ...

Страница 32: ...28 Owner s Manual for Flameless Heat Cart Installation Diagrams Engine Harness 2 of 3 ...

Страница 33: ...Owner s Manual for Flameless Heat Cart 29 Installation Diagrams Engine Harness 3 of 3 ...

Страница 34: ...t Cart Installation Diagrams Hydraulic System Schematic M 1 H1 H1 H1 H1 H1 H1 M 1 P1 H1 V1 V1 Large Hydraulic Exchanger Small Hydraulic Exchanger Hydraulic Oil Tank Fan Pressure Regulating 3 Way Valve Start up Bypass 3 Way Valve Filters ...

Страница 35: ...Owner s Manual for Flameless Heat Cart 31 Installation Diagrams Hydraulic Heat System ENGINE RADIATOR C60 HYD EXCHANGER LARGE EXHAUST EXCHANGER ...

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Страница 37: ...Owner s Manual for Flameless Heat Cart 33 Installation Diagrams This page intentionally left blank ...

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Страница 39: ......

Страница 40: ...ights reserved Specifications are subject to change without notice No reproduction allowed in any form without prior written consent from Generac Mobile Products LLC Generac Mobile Products LLC 215 Power Drive Berlin WI 54923 GeneracMobileProducts com 800 926 9768 920 361 4442 ...

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