Wacker Neuson E3000 User manual

Operator’s Manual

Hydronic Surface Heater

E3000

Type E3000

Document 5000188154

Date 1115

Version 05

Language EN

5000188154

All rights, including copying and distribution rights, are reserved.

This publication may be photocopied by the original purchaser of the

machine. Any other type of reproduction is prohibited without express

written permission from Wacker Neuson Production Americas LLC.

Any type of reproduction or distribution not authorized by Wacker

Neuson Production Americas LLC represents an infringement of valid

copyrights. Violators will be prosecuted.

Trademarks

All trademarks referenced in this manual are the property of their

respective owners.

Manufacturer

Wacker Neuson Production Americas LLC

N92W15000 Anthony Avenue

Menomonee Falls, WI 53051 U.S.A.

Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957

www.wackerneuson.com

Original instructions

This Operator’s Manual presents the original instructions. The original

language of this Operator’s Manual is American English.

E 3000 Foreword

wc_tx002028gb.fm 3

Foreword

This heater is designed and approved for use as a construction heater in

accordance with Standard ANSI Z83.7–CSGA 2.14. CHECK WITH YOUR LOCAL

FIRE SAFETY AUTHORITY IF YOU HAVE QUESTIONS ABOUT APPLICATIONS.

Other standards govern the use of fuel gases and heat producing products in

specific applications. Your local authority can advise you about these.

THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE

REGULATIONS OF THE AUTHORITIES HAVING JURISDICTION.

WARNING

Risk of personal injury or machine damage from improper use.

fBefore using the machine, read and understand all instructions and follow them

carefully.

fThe manufacturer is not responsible for damages to goods or persons due to

improper use of this machine.

WARNING

Failure to comply with the precautions and instructions provided with this machine

can result in death, serious injury, and property loss or damage from fire, explosion,

burns, asphyxiation, carbon monoxide poisoning, and/or electric shock.

fBefore using the machine, read and understand all precautions and instructions

that have been provided. Follow them carefully.

fOnly persons who can understand and follow the precautions and instructions

should use or service this machine.

fContact the manufacturer if you need assistance with operating the machine or

need replacement manuals or labels.

WARNING

Work site fire, burn, inhalation, and explosion hazards.

fKeep solid combustibles, such as building materials, paper, or cardboard at a

safe distance away from the machine as recommended by the instructions.

fNever use this machine in spaces which do or may contain volatile or airborne

combustibles, or products such as gasoline, solvents, paint thinner, dust parti-

cles, or unknown chemicals.

WARNING

Not for use in homes or recreational vehicles. Installing this machine in a home or

RV may result in fire, explosion, property damage, personal injury, or death.

fOperate the machine only for applications specified in Machine Description and

Intended Use.

Foreword

wc_tx002028gb.fm

SAVE THESE INSTRUCTIONS—This manual contains important instructions for

the machine models below. These instructions have been written expressly by

Wacker Neuson Production Americas LLC and must be followed during installation,

operation, and maintenance of the machines.

Machine

documentation

From this point forward in this documentation, Wacker Neuson Production

Americas LLC will be referred to as Wacker Neuson.

Keep a copy of the Operator’s Manual with the machine at all times.

Use the separate Parts Book supplied with the machine to order replacement

parts.

Refer to the separate Repair Manual for detailed instructions on servicing and

repairing the machine.

If you are missing any of these documents, please contact Wacker Neuson to

order a replacement or visit www.wackerneuson.com.

When ordering parts or requesting service information, be prepared to provide

the machine model number, item number, revision number, and serial number.

Expectations

for

information in

this manual

This manual provides information and procedures to safely operate and

maintain the above Wacker Neuson model(s). For your own safety and to

reduce the risk of injury, carefully read, understand, and observe all instructions

described in this manual.

Wacker Neuson expressly reserves the right to make technical modifications,

even without notice, which improve the performance or safety standards of its

machines.

The information contained in this manual is based on machines manufactured

up until the time of publication. Wacker Neuson reserves the right to change

any portion of this information without notice.

CALIFORNIA

Proposition

65 Warning

Engine exhaust, some of its constituents, and certain vehicle components, contain

or emit chemicals known to the State of California to cause cancer and birth

defects or other reproductive harm.

Laws

pertaining to

spark

arresters

NOTICE: State Health Safety Codes and Public Resources Codes specify that in

certain locations spark arresters be used on internal combustion engines that use

hydrocarbon fuels. A spark arrester is a device designed to prevent accidental

discharge of sparks or flames from the engine exhaust. Spark arresters are

qualified and rated by the United States Forest Service for this purpose. In order to

Machine Item Number Revision

E 3000 0620158 225 and higher

E 3000G 0620219 225 and higher

E 3000 LB 0620678 225 and higher

E 3000 LB-G 0620679 225 and higher

E 3000 LB-G 52000004952 100 and higher

Foreword

wc_tx002028gb.fm 5

comply with local laws regarding spark arresters, consult the engine distributor or

the local Health and Safety Administrator.

Manufacturer’s

approval

This manual contains references to approved parts, attachments, and

modifications. The following definitions apply:

Approved parts or attachments are those either manufactured or provided by

Wacker Neuson.

Approved modifications are those performed by an authorized Wacker

Neuson service center according to written instructions published by Wacker

Neuson.

Unapproved parts, attachments, and modifications are those that do not

meet the approved criteria.

Unapproved parts, attachments, or modifications may have the following

consequences:

Serious injury hazards to the operator and persons in the work area

Permanent damage to the machine which will not be covered under warranty

Contact your Wacker Neuson dealer immediately if you have questions about

approved or unapproved parts, attachments, or modifications.

Foreword

wc_tx002028gb.fm

Table of Contents

E 3000

wc_bo5000188154_05TOC.fm 7

Foreword 3

1 Safety Information 11

1.1 Signal Words Used in this Manual ..................................................... 11

1.2 Machine Description and Intended Use ............................................. 12

1.3 Safety Guidelines for Operating the Machine ..................................... 13

1.4 Safety Guidelines for Lifting the Machine ........................................... 14

1.5 Safety Guidelines for Operating Combustion Burners ....................... 15

1.6 Safety Guidelines for Operating Gensets ........................................... 16

1.7 Service Safety .................................................................................... 18

1.8 Safety Guidelines for Towing the Machine ......................................... 20

1.9 Reporting Safety Defects ................................................................... 21

2 Labels 22

2.1 Label 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

4.2 Internal Components .......................................................................... 41

4.3 Rear Components .............................................................................. 42

4.4 Pumps, Gauges, and Valves .............................................................. 43

4.5 Control Panel ...................................................................................... 44

4.6 Control Panel Components ................................................................ 45

4.7 Genset Control Panel ......................................................................... 46

4.8 Preparing the Machine for First Use ................................................... 47

4.9 Breaking in the Genset ....................................................................... 47

4.10 General Sequence of Operation ......................................................... 48

4.11 Checking the HTF Level ..................................................................... 49

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wc_bo5000188154_05TOC.fm

4.12 Recommended Fuel ............................................................................50

4.13 Refueling the Machine .........................................................................51

4.14 Positioning the Machine ......................................................................52

4.15 Pre-Starting Checks ............................................................................54

4.16 Connecting Power to the Machine ......................................................57

4.17 Starting and Stopping the Generator ...................................................58

4.18 Applying Power to the Machine ...........................................................59

4.19 Preheating the HTF .............................................................................60

4.20 Initiating HTF Flow ..............................................................................61

4.21 Setting the Operating Temperature .....................................................62

4.22 Unwinding and Positioning the Hoses .................................................63

4.23 Hose Spacing Guidelines ....................................................................64

4.24 Monitoring the Operating Parameters .................................................65

4.25 Rewinding the Hoses ..........................................................................66

4.26 Shutting Down and Packing Up the Machine ......................................68

4.27 Resetting a Low HTF Fault ..................................................................69

4.28 Quick-Connect Coupling Usage and Care ..........................................72

4.29 Operating States of 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 HX 50 Heat Exchangers ...........................................90

5.9 Connecting Four HX 50 Heat Exchangers ..........................................92

5.10 Connecting Three HX 50 Heat Exchangers ........................................94

5.11 Connecting Two HX 50 Heat Exchangers ...........................................96

5.12 Connecting One HX 50 Heat Exchanger .............................................98

5.13 Connecting Three HX 100 Heat Exchangers ....................................100

5.14 Connecting Two HX 100 Heat Exchangers .......................................102

5.15 Connecting One HX 100 Heat Exchanger .........................................104

5.16 Connecting Two HX 200 Heat Exchangers .......................................106

5.17 Connecting One HX 200 Heat Exchanger .........................................108

6 Burner Setup—Oil 109

6.1 Factory Settings ................................................................................109

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wc_bo5000188154_05TOC.fm 9

6.2 Setting up the Burner ....................................................................... 109

6.3 Setting/Checking the Electrodes ...................................................... 112

6.4 Replacing the Burner Nozzle ............................................................ 114

6.5 Setting the “Z” Distance .................................................................... 116

6.6 Adjusting the Air Settings ................................................................. 118

6.7 Adjusting the Fuel Pressure ............................................................. 119

7 Burner Setup—Gas 120

7.1 Factory Settings ............................................................................... 120

7.2 Restrictions for Connecting the Gas Supply ..................................... 121

7.3 Setting up the Burner ....................................................................... 122

7.4 Removing and Installing the Combustion Head ............................... 124

7.5 Adjusting the Ionization Probe and the Electrode ............................ 126

7.6 Changing the Burner Diaphragm ...................................................... 127

7.7 Checking and Adjusting the Air Damper (Gate) Setting ................... 128

7.8 Adjusting the Combustion 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 Lubricating the Hose Reel System ................................................... 145

8.9 Cleaning the Turbulators and the Exhaust Ducting .......................... 146

8.10 Inspecting/Replacing the Rope Gasket ............................................ 148

8.11 Removing the Oil Burner .................................................................. 149

8.12 Installing the Burner ......................................................................... 150

8.13 Storing the Machine ......................................................................... 151

8.14 Storing the Genset ........................................................................... 152

8.15 Preparing the Machine for Seasonal Operation ............................... 153

8.16 Connecting and Maintaining the Battery .......................................... 154

9 Genset Maintenance 155

9.1 Periodic Maintenance Schedule ....................................................... 155

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9.2 Checking the Engine Oil ....................................................................156

9.3 Changing the Engine Oil and Oil Filter ..............................................157

9.4 Checking the Engine Coolant Level ..................................................159

9.5 Replacing the Air Filter Element ........................................................160

9.6 Replacing Engine Fuel Filter .............................................................161

9.7 Changing Engine Coolant .................................................................163

9.8 Genset Shut-Down Codes .................................................................165

10 Troubleshooting 169

10.1 Troubleshooting the Machine ............................................................169

10.2 Troubleshooting the Oil Burner .........................................................171

10.3 Troubleshooting 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 Circuit ......................................................................206

12.6 Gas Train Schematic .........................................................................207

12.7 Generator ..........................................................................................208

12.8 Trailer Plug — Wiring Diagram ..........................................................209

12.9 Trailer Junction Box — Wiring Diagram ............................................210

12.10 Trailer Lights and Brakes — Wiring Diagram ....................................211

12.11 Trailer Lights and Brakes — Components ........................................212

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