Wacker Neuson E3000 Operator's Manual
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Wacker Neuson E3000 Operator's Manual

Hydronic surface heater
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Operator's Manual
Hydronic Surface Heater
E3000
5000188154
1115
05
EN
E3000
5 0 0 0 1 8 8 1 5 4

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Summary of Contents for Wacker Neuson E3000

  • Page 1 Operator’s Manual Hydronic Surface Heater E3000 Type E3000 Document 5000188154 Date 1115 Version Language 5 0 0 0 1 8 8 1 5 4...
  • Page 2 Copyright notice © Copyright 2015 by Wacker Neuson Production Americas LLC 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.

  • Page 3: Foreword

    E 3000 Foreword 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.
  • Page 4 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.
  • Page 5 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.
  • Page 6 Foreword wc_tx002028gb.fm...

  • Page 7: Table Of Contents

    E 3000 Table of Contents Foreword Safety Information Signal Words Used in this Manual ............. 11 Machine Description and Intended Use ..........12 Safety Guidelines for Operating the Machine ........13 Safety Guidelines for Lifting the Machine ........... 14 Safety Guidelines for Operating Combustion Burners ....... 15 Safety Guidelines for Operating Gensets ...........
  • Page 8 Table of Contents E 3000 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...
  • Page 9 E 3000 Table of Contents Setting up the Burner ............... 109 Setting/Checking the Electrodes ............112 Replacing the Burner Nozzle ............114 Setting the “Z” Distance ..............116 Adjusting the Air Settings ..............118 Adjusting the Fuel Pressure ............. 119 Burner Setup—Gas Factory Settings ................
  • Page 10 Table of Contents E 3000 Checking the Engine Oil ..............156 Changing the Engine Oil and Oil Filter ..........157 Checking the Engine Coolant Level ..........159 Replacing the Air Filter Element ............160 Replacing Engine Fuel Filter .............161 Changing Engine Coolant ..............163 Genset Shut-Down Codes ..............165 10 Troubleshooting 10.1 Troubleshooting the Machine ............169...

  • Page 11: Safety Information

    E 3000 Safety Information Safety Information Signal Words Used in this Manual This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE signal words which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol.

  • Page 12: Machine Description And Intended Use

    In addition, when used with other Wacker Neuson accessories, this machine can be used to heat air. This machine has been designed and built strictly for the intended use(s) described above.

  • Page 13: Safety Guidelines For Operating The Machine

    Familiarize yourself with the location and proper use of all controls and safety devices. Contact Wacker Neuson for additional training if necessary. When operating this machine: Do not allow improperly trained people to operate the machine. People operating the machine must be familiar with the potential risks and hazards associated with it.

  • Page 14: Safety Guidelines For Lifting The Machine

    Safety Information E 3000 When operating this machine: Do not operate a machine in need of repair. Personal Wear the following Personal Protective Equipment (PPE) while operating this Protective machine: Equipment Close-fitting work clothes that do not hinder movement (PPE) Safety glasses with side shields Hearing protection Safety-toed footwear...

  • Page 15: Safety Guidelines For Operating Combustion Burners

    E 3000 Safety Information Safety Guidelines for Operating Combustion Burners When using the machine: Clean up any spilled fuel immediately. Replace the fuel tank cap after refueling the machine. Refill the fuel tank in a well-ventilated area. Shut down the generator, if equipped, when refueling. When using the machine: DANGER Exhaust gas from the burner contains carbon monoxide, a deadly poison.

  • Page 16: Safety Guidelines For Operating Gensets

    Follow instructions carefully. Should questions arise during operation or service of this equipment, contact your Wacker Neuson dealer. General Keep a multi-class, type ABC or equivalent fire extinguisher at hand when using precautions the genset.
  • Page 17 E 3000 Safety Information Before Know how to start, operate, and stop the genset before starting it. operating the Obtain the proper training for operating the genset. Do not allow untrained genset personnel to operate or service the genset. Check the fuel lines and the fuel tank for leaks and cracks before starting the engine.

  • Page 18: Service Safety

    Machine When servicing or maintaining the machine: modifications Use only accessories/attachments that are approved by Wacker Neuson. When servicing or maintaining the machine: Do not defeat safety devices. Do not modify the machine without the express written approval of Wacker Neuson.
  • Page 19 E 3000 Safety Information When cleaning the machine: Do not clean the machine while it is running. Never use gasoline or other types of fuels or flammable solvents to clean the machine. Fumes from fuels and solvents can become explosive. Personal Wear the following Personal Protective Equipment (PPE) while servicing or Protective...

  • Page 20: Safety Guidelines For Towing The Machine

    Safety Information E 3000 Safety Guidelines for Towing the Machine WARNING Risk of severe injury or death. Improper trailer condition and towing technique can lead to an accident. Obey the trailer manufacturer’s instructions and the instructions below to reduce the risk of an accident. When towing the machine: Do not tow the machine if the towing vehicle’s hitch or the trailer’s coupler are damaged.

  • Page 21: Reporting Safety Defects

    If you believe your trailer has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Wacker Neuson. If NHTSA receives similar complaints, it may open an investigation; and if it finds that a safety defect exists in a group of trailers, it may order a recall and remedy campaign.

  • Page 22: Labels

    Labels E 3000 Labels Label Locations wc_gr008850 wc_si000643gb.fm...
  • Page 23 E 3000 Labels wc_gr008849 wc_si000643gb.fm...

  • Page 24: Label Meanings

    Labels E 3000 Label Meanings Ref. Label Definition For machines powered by For machines powered by the generator: the power utility: Use a 50-50 blend of #2 diesel Use 100% #1 diesel plus and #1 diesel plus additives, additives or 100% K1 kero- or a 50-50 blend of #2 diesel sene plus additives when and K1 kerosene plus addi-...
  • Page 25 E 3000 Labels Ref. Label Definition Heat Transfer Fluid level. This label indicates the minimum and maximum level for the Heat Transfer Fluid. This label is located adjacent to a sight gauge on the Heat Trans- fer Fluid reservoir. WARNING! Do not engage trailer jack while transporting WARNING the machine.
  • Page 26 Labels E 3000 Ref. Label Definition Tie-down location marker. NOTICE! CAUTION Lift point. Attach lifting device in this location. VORSICHT PRECAUCION PRECAUTION WARNING! WARNING Hand entanglement hazard. Moving parts can crush and cut. Do not operate with guard removed. 173224 WARNUNG ADVERTENCIA AVERTISSEMENT...
  • Page 27 E 3000 Labels Ref. Label Definition Not a step. Weight/mass label: This label indicates the total weight of the machine, including the 8582 trailer and a full fuel tank. 3900 CAUTION This machine uses diesel fuel. DANGER Asphyxiation hazard. Using a Hydronic Surface Heater indoors CAN KILL YOU IN MINUTES.
  • Page 28 Labels E 3000 Ref. Label Definition Machine rating label: This label indicates rating information for the machine. WARNING! Lugnuts factory torqued to 110 ft.lbs. Verify lugnuts are properly torqued before trans- porting. Failure to heed above warning could result in wheel loss which can cause injury or death.
  • Page 29 E 3000 Labels Ref. Label Definition CAUTION! CAUTION Pressurized contents. Do not open when hot! VORSICHT ATENCION ATTENTION 183255 WARNING! WARNING Never operate in an explosive environment or near flammable vapors, fuels Never operate in an explosive environment or combustibles. Explosion or fire may occur. Risk of severe injury or death. ADVERTENCIA or near flammable vapors, fuels or combusti- Nunca opere en un ambiente explosivo o cerca de los vapores inflamables,...

  • Page 30: Lifting And Transporting

    Lifting and Transporting E 3000 Lifting and Transporting Lifting the Machine Requirements Properly rated lifting equipment (crane or hoist). See Chapter Technical Data. Machine stopped. See topic Stopping the Machine. All doors and access covers closed and secured. WARNING Crushing hazard. You may be crushed if the lifting devices fail. Never stand under, or get onto, the machine while it is being lifted or moved.

  • Page 31: Preparing The Machine For Transport On A Truck Or Trailer

    E 3000 Lifting and Transporting Preparing the Machine for Transport on a Truck or Trailer Requirements Machine stopped. Flatbed truck or trailer capable of supporting the machine’s weight. Chains, hooks, or straps capable of supporting the machine’s weight. WARNING Crushing hazard. Improperly securing the machine can lead to a crushing hazard. Use only the designated tie-down points to secure the machine to a truck or trailer.

  • Page 32: Transporting The Machine On A Truck Or Trailer

    Lifting and Transporting E 3000 Transporting the Machine on a Truck or Trailer Requirements Machine stopped. See topic Stopping the Machine. All doors and access covers closed and secured. WARNING Crushing hazard. Improperly securing the machine can lead to a crushing hazard. Use only the designated tie-down points to secure the machine.
  • Page 33 E 3000 Lifting and Transporting Continued from the previous page. Secure the 5. Install properly rated securing mechanisms (d) such as chains or straps. machine 6. Install chocks (e) under all four wheels. Result The machine is ready to be transported. ghi_tx001160gb.fm...

  • Page 34: Before Towing Checklist

    Lifting and Transporting E 3000 Before Towing Checklist Before towing the machine, check the licensing requirements for trailers in your area. Also check the following items: Hitch and coupler Check that the towing vehicle and hitch have a rating equal to or greater than the GVWR of the machine.

  • Page 35: Towing The Machine

    E 3000 Lifting and Transporting Towing the Machine WARNING Risk of severe injury or death. Improperly torqued lug nuts can lead to loss of wheels. Loss of wheels can cause an accident, severe injury or death. Tighten the lug nuts to the proper torque before towing the machine. NOTICE: The towing vehicle must be equipped with a Class III or above hitch.

  • Page 36: Testing The Breakaway System (Electric Brakes)

    Lifting and Transporting E 3000 Testing the Breakaway System (Electric Brakes) Requirements Voltmeter Battery charger or backup battery (charged) When Test the breakaway system: Before towing Monthly if the machine is not in service Procedure Perform the following procedure to test the breakaway system. NOTICE: Disconnect the trailer wiring plug from the tow vehicle before testing.
  • Page 37 E 3000 Lifting and Transporting Continued from the previous page. 5. If the brakes did not function, check the voltage of the breakaway battery. To do a. Remove the cover of the battery box. b. Remove the wires connected to the breakaway battery (d). c.

  • Page 38: Hazardous Materials Placards

    Lifting and Transporting E 3000 Hazardous Materials Placards Hazardous The Pipeline and Hazardous Materials Safety Administration (PHMSA) requires materials that hazardous materials placards be placed on this machine when transporting it placards unless the fuel tank has been drained and purged of all fuel and residue. Before transporting the machine: 1.
  • Page 39 E 3000 Lifting and Transporting Notes ghi_tx001160gb.fm...

  • Page 40: Operation

    Operation E 3000 Operation External Components wc_gr008851 Ref. Description Ref. Description Hitch (ball or pintle) Fender Tie-down Onan genset (option) Fuel tank Jack stand Fuel tank cap Tandem axles Performance monitoring light Lifting bail wc_tx001951gb.fm...

  • Page 41: Internal Components

    E 3000 Operation Internal Components wc_gr008296 Ref. Description Ref. Description Hydronic heater Fill valve #3 Burner (oil burning shown) HTF pumps Suction valve #2 Low-level shut-down device Fuel filter Thermocouple Battery Temperature/pressure gauges Fuel sight gauge HTF filter Fuel sight gauge valve Motor (HTF pump) This hydronic heater operates at zero (atmospheric) pressure and is not subject to regulations applicable to pressurized “boilers”.

  • Page 42: Rear Components

    Operation E 3000 Rear Components Ref. Description Ref. Description Control panel Hose reels and hose Heat Transfer Fluid (HTF) return Pump Pack supply connections plumbing HTF supply plumbing Duplex receptacle Hose reel brake T-handle Operator’s Manual holder Rewind system foot control pedal Thermal switch (snap switch) HTF expansion tank sightglass —...

  • Page 43: Pumps, Gauges, And Valves

    E 3000 Operation Pumps, Gauges, and Valves Pumps and Gauges Ref. Description Left pump Return flow indicator Accessory HTF return thermometer Main HTF return thermometer Check valves Pump pressure gauge Right pump Valves Valve # Description Pump Pack supply and drain valve Pump suction valve (behind hose reel) HTF fill valve (behind hose reel)

  • Page 44: Control Panel

    Operation E 3000 Control Panel wc_gr008606 wc_tx001951gb.fm...

  • Page 45: Control Panel Components

    E 3000 Operation Control Panel Components Description Function Main breaker 1 Controls power to electrical circuit 1. Hour meter Meters usage of the machine. Main breaker 2 Controls power to the pump circuit (20A) Circuit 2 GFCI Provides protection for the operator. Temperature control Allows the user to control the HTF target application temperature.

  • Page 46: Genset Control Panel

    Operation E 3000 Genset Control Panel wc_gr008140 Description Oil fill cap and dipstick Coolant recovery access panel Coolant level sightglass Control switch and status light Line circuit breakers Coolant fill access panel wc_tx001951gb.fm...

  • Page 47: Preparing The Machine For First Use

    1. Make sure all loose packaging materials have been removed from the machine. 2. Check the machine and its components for damage. If there is visible damage, do not operate the machine! Contact your Wacker Neuson dealer immediately for assistance.

  • Page 48: General Sequence Of Operation

    Operation E 3000 4.10 General Sequence of Operation Follow the sequence of operation below. Refer to the specific topic for details. Task When/Where See Topic 1. Check HTF level. Before leaving for the job site. 4.11 / 4.15 Or, when at the job site before 2.

  • Page 49: Checking The Htf Level

    E 3000 Operation 4.11 Checking the HTF Level When Before leaving for the job site, or Before beginning operation at the job site Prerequisites The machine is level. The machine is cool. Procedure The Heat Transfer Fluid (HTF) level must be between the marks on the sightglass (c).

  • Page 50: Recommended Fuel

    Operation E 3000 4.12 Recommended Fuel Low ambient temperatures cause diesel fuels to gel. Gelled fuels will cause burner ignition failure and/or burner fuel pump damage. Always use the proper fuel for the conditions. Fuel Blend Guide Lowest expected ambient Generator-powered Shore-powered temperature °F (°C)

  • Page 51: Refueling The Machine

    E 3000 Operation 4.13 Refueling the Machine Requirements Machine shut down Machine level with the ground Diesel fuel supply Procedure Perform the procedure below to refuel the machine. Note: On models with generators, it is not necessary to fill the generator’s fuel tank.

  • Page 52: Positioning The Machine

    Do not operate the machine near flammable vapors, fuels, or combustibles. CO Alarms Because this machine produces carbon monoxide (CO), Wacker Neuson recommends that CO alarms be installed in all structures in close proximity to the machine. CO alarms provide an extra measure of protection against this poison that you cannot see or smell.
  • Page 53 E 3000 Operation Continued from the previous page. Procedure Perform the following procedure to position the machine. 1. Place the machine near the application area (a) on solid, stable, and level ground. wc_gr008529 2. For machines with trailers, install chocks (b) under the wheels. Result The machine is now properly positioned.

  • Page 54: Pre-Starting Checks

    Operation E 3000 4.15 Pre-Starting Checks Requirements Machine properly positioned Power connected to the machine Checks Before starting the machine, check the following items: Fuel System Fuel sight gauge valve Check that the fuel sight gauge valve is open. Fuel sight gauge Check that the fuel tank is full.
  • Page 55 E 3000 Operation Suction valve (#2) Check that suction valve (#2) is open. HTF fill valve (#3) Check that HTF fill valve (#3) is closed and locked with the locking pin. NOTICE: The HTF fill valve must remain closed and locked during normal operation.
  • Page 56 Operation E 3000 Hydronic heater Inspect for signs of exhaust leaks. See topic Inspecting/ Replacing the Rope Gasket. wc_gr008603 Genset (g) (if equipped) Check oil level. See topic Checking the Engine Oil. Inspect for signs of fuel and exhaust leaks wc_gr008141 Result The machine is ready to have power applied.

  • Page 57: Connecting Power To The Machine

    E 3000 Operation 4.16 Connecting Power to the Machine Prerequisites Power source Machine properly positioned WARNING Fire hazard and electric shock hazard. The use of undersized extension cords can lead to fire and electric shock. Fire and electric shock can cause severe injury. Do not use undersized extension cords.

  • Page 58: Starting And Stopping The Generator

    Operation E 3000 4.17 Starting and Stopping the Generator Background Only general starting and stopping procedures for the generator are included in this manual. See the generator manufacturer’s operation manual for detailed procedures. Starting Perform the procedure below to start the generator. 1.

  • Page 59: Applying Power To The Machine

    E 3000 Operation 4.18 Applying Power to the Machine Requirements Pre-starting checks have been completed Power connected to the machine Procedure Follow the procedure below to apply power to the machine. 1. Move both circuit breaker switches (a) to the ON position. wc_gr008607 2.

  • Page 60: Preheating The Htf

    Operation E 3000 4.19 Preheating the HTF NOTICE: Starting the machine with frozen or partially frozen Heat Transfer Fluid (HTF) will permanently damage the pumps. Preheat the HTF when ambient air temperature is below -26°C (-15°F). Requirements HTF reservoir full Machine powered up Procedure Follow the procedure below to preheat the HTF.

  • Page 61: Initiating Htf Flow

    E 3000 Operation 4.20 Initiating HTF Flow Requirements Heat Transfer Fluid (HTF) preheated. See topic Preheating the HTF. Gloves CAUTION Burn hazard. The hoses and components of the plumbing system may be very hot. Hot hoses and hot plumbing components may cause burns. Wear gloves when handling hot hoses or hot plumbing components.

  • Page 62: Setting The Operating Temperature

    Operation E 3000 Continued from the previous page. 4. Move the left pump ON-OFF switch (d) to the ON position. 5. Check the pump pressure gauge (e). The following should occur: During the first minute of operation, the pressure should build to as high as 170 psi.

  • Page 63: Unwinding And Positioning The Hoses

    E 3000 Operation 4.22 Unwinding and Positioning the Hoses Requirements HTF preheated if applicable HTF flow initiated CAUTION Burn hazard. The hoses and components of the plumbing system may be very hot. Hot hoses and hot plumbing components may cause burns. Wear gloves when handling hot hoses and plumbing components.

  • Page 64: Hose Spacing Guidelines

    When laying hose in the application area, the space between individual lines of hose significantly affects the progress of the application. Although it is impossible to predict the ambient conditions for each job site, Wacker Neuson Corporation recommends observing the following guidelines to maximize efficiency.

  • Page 65: Monitoring The Operating Parameters

    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 Neuson Product Support for detailed information. Strobe light Flashing strobe signifies that all systems are OK.

  • Page 66: Rewinding The Hoses

    Operation E 3000 4.25 Rewinding the Hoses Requirements All accessories off, if applicable Machine turned on CAUTION Burn hazard. The hoses and components of the plumbing system may be very hot. Hot hoses and hot plumbing components may cause burns. Wear gloves when handling hot hoses and plumbing components.
  • Page 67 E 3000 Operation Continued from the previous page. NOTICE: Disengage the clutch before reaching the hose end. Failure to comply may damage the machine. 6. Release the foot pedal to disengage the clutch before reaching the hose end. 7. Manually wind the remainder of the hose onto the reel. wc_gr008535 wc_gr008534 8.

  • Page 68: Shutting Down And Packing Up The Machine

    Operation E 3000 4.26 Shutting Down and Packing Up the Machine Shutting Perform the procedure below to shut down the machine. down 1. Turn off all accessories if applicable. 2. Rewind the hoses. See topic Rewinding the Hoses. 3. Move the burner ON-OFF switch (a) to the OFF position. LEFT RIGHT PUMP...

  • Page 69: Resetting A Low Htf Fault

    E 3000 Operation 4.27 Resetting a Low HTF Fault Requirements Genuine Wacker Neuson Heat Transfer Fluid, or Dowfrost HD 50 Heat Transfer Fluid NOTICE: Use only factory-recommended Heat Transfer Fluid (HTF). Failure to do so may damage the machine. Background The HTF reservoir includes a sensor that will trigger the low-level shut-down device to stop the machine’s function if the HTF falls below the minimum operational...
  • Page 70 Operation E 3000 Continued from the previous page. 7. Lift and hold the HTF fill switch (b) in the ON position (I) and watch the HTF reservoir sightglass (c)—release the HTF fill switch when the HTF level is seen in the HTF reservoir sightglass. NOTICE: Do not overfill the HTF reservoir.
  • Page 71 E 3000 Operation Continued from the previous page. 10.Move valve #3 to the normal position. 11.Remove the fill hose from the HTF container 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.

  • Page 72: Quick-Connect Coupling Usage And Care

    Operation E 3000 4.28 Quick-Connect Coupling Usage and Care CAUTION Burn hazard. The hoses and components of the plumbing system may be very hot. Hot hoses and hot plumbing components may cause burns. Wear gloves when handling hot hoses and hot plumbing components. Precautions Do not join or separate quick-connect couplings when the pressure gauge indicates that the system is pressurized.

  • Page 73: Operating States Of The Beckett Burner Controller

    E 3000 Operation 4.29 Operating States of the Beckett Burner Controller Operating State wc_gr007662 Burner states The burner control has several states that it sequences through during normal operation. These operating states are described below. State Action or Function Standby As soon as power is supplied to the burner control, the burner control enters the standby state in which it will remain until there is a call for heat or power is disconnected.
  • Page 74 Operation E 3000 State Action or Function Ignition The ignition carryover state starts as soon as the flame is established. carryover During this state: The fuel shut-off valve is open (energized). Pressurized fuel atomizes at the burner nozzle. The atomized fuel is ignited by the electrodes. The electrodes stay powered for up to 10 seconds after flame is sensed.
  • Page 75 E 3000 Operation Lockout The lockout state is described below. State Action or Function The burner will enter the lockout state for the following reasons: Lockout Trial for ignition time has expired without flame being estab- lished. Cad cell detects flame at the end of the valve-on delay state. Recycle time budget expires.
  • Page 76 Operation E 3000 Pump prime The pump prime mode is described below. State Action or Function Pump prime During the pump prime mode, the cad cell is disregarded, allowing the technician to prime the pump without having to jumper the cad cell. This mode lasts 4 minutes.
  • Page 77 E 3000 Operation Notes wc_tx001951gb.fm...

  • Page 78: Accessories

    Accessories E 3000 Accessories Available Accessories To increase the machine’s capabilities and capacities, the following Wacker Neuson accessories are available. Description Ref. Description Hose Handling System (HHS3002) 1-2 Adapter Heat Exchanger (HX 50) 2-1 Adapter Heat Exchanger (HX 100) Accessory hoses (various lengths) Heat Exchanger (HX 200) Single (SPP) or Dual Pump Pack (DPP)

  • Page 79: Expanding The Surface Heating Capacity

    Expanding the Surface Heating Capacity Background The E 3000 can be combined with Wacker Neuson Hose Handling Systems (HHS 3002) and Dual Pump Packs (DPP) to increase the surface heating capacity. The typical configurations are shown below; however, this does not represent all possible configurations.

  • Page 80: Expanded Operation Using One Hhs 3002 And One Dpp

    Accessories E 3000 Expanded Operation Using One HHS 3002 and One DPP Requirements Machine stopped One HHS 3002 Hose Handling System One DPP Dual Pump Pack Procedure Perform the procedure below to expand the machine with one Hose Handling System (HHS) and one Dual Pump Pack (DPP). 1.
  • Page 81 E 3000 Accessories Continued from the previous page. wc_gr008541 Description Condition Pump pack supply valve 1 Open after connection Right HTF supply valve Open after connection Cross connect valve Closed Left HTF supply valve Open after connection Pump pack supply valve 2 Closed (no connections) Connected to E 3000 and HHS 3002 Hose loop from left reel...

  • Page 82: Expanded Operation Using Two Hhs 3002 And Two Dpp

    Accessories E 3000 Expanded Operation Using Two HHS 3002 and Two DPP Requirements Machine stopped Two HHS 3002 Hose Handling Systems Two DPP Dual Pump Packs Two 2-1 adapters Procedure Perform the procedure below to expand the machine with two Hose Handling Systems (HHS) and two Dual Pump Packs (DPP).
  • Page 83 E 3000 Accessories Continued from the previous page. wc_gr008542 This procedure continues on the next page. ghi_tx001162gb.fm...
  • Page 84 Accessories E 3000 Continued from the previous page. Description Condition Pump pack supply valve 1 Open after connection Right HTF supply valve Open after connection Cross connect valve Closed Left HTF supply valve Open after connection Pump pack supply valve 2 Open after connection First DPP Connected to E 3000 and HHS 3002...

  • Page 85: Mounting And Connecting The Auxiliary Pump Panel

    Machine shut down Power disconnected Background The Wacker Neuson Auxiliary Pump Panel (APP) is an electrical device that communicates with the main machine’s systems 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.
  • Page 86 Accessories E 3000 Continued from the previous page. Electrical After mounting, carry out the steps below to complete the electrical connections. connections 1. Connect the DIN leader (a) from the main control panel to the corresponding DIN leader on the APP (b). 2.

  • Page 87: Using Heat Exchangers To Heat Air

    Accessories Using Heat Exchangers to Heat Air Background The E 3000 can be combined with Wacker Neuson HX 50, HX 100, or HX 200 Heat Exchangers to convert the heating application from surface to air. Configuration In order to connect Heat Exchangers to the machine, additional accessories (Sin-...

  • Page 88: Connecting Six Hx 50 Heat Exchangers

    Accessories E 3000 Connecting Six HX 50 Heat Exchangers Requirements Six HX 50 Heat Exchangers Four 2-1 adapters Three 1-2 adapters One Single Pump Pack (SPP) Auxiliary Pump Pack (APP) (See topic Mounting the Auxiliary Pump Panel.) Connect Perform the procedure below to connect the Heat Exchanger to the machine. adapters 1.
  • Page 89 E 3000 Accessories Continued from the previous page. Run the NOTICE: Only start the pumps when the Heat Exchangers are connected. Starting machine the pumps when the Heat Exchangers are not connected will cause excess system pressure which may damage the pumps. 1.

  • Page 90: Connecting Five Hx 50 Heat Exchangers

    Accessories E 3000 Connecting Five HX 50 Heat Exchangers Requirements Machine stopped Five HX 50 Heat Exchangers Three 2-1 adapters Two 1-2 adapters One Single Pump Pack (SPP) Auxiliary Pump Pack (APP) (See topic Mounting the Auxiliary Pump Panel.) Connect Perform the procedure below to connect the Heat Exchangers to the machine.
  • Page 91 E 3000 Accessories HX 50 HX 50 HX 50 HX 50 HX 50 wc_gr008557 ghi_tx001162gb.fm...

  • Page 92: Connecting Four Hx 50 Heat Exchangers

    Accessories E 3000 Connecting Four HX 50 Heat Exchangers Requirements Machine stopped Four HX 50 Heat Exchangers Two 2-1 adapters Two 1-2 adapters Connect Perform the procedure below to connect the Heat Exchangers to the machine. adapters 1. Connect a 2-1 adapter (x) to the left return plumbing rack (LR). 2.
  • Page 93 E 3000 Accessories HX 50 HX 50 HX 50 HX 50 wc_gr008558 ghi_tx001162gb.fm...

  • Page 94: Connecting Three Hx 50 Heat Exchangers

    Accessories E 3000 5.10 Connecting Three HX 50 Heat Exchangers Requirements Machine stopped Three HX 50 Heat Exchangers One 2-1 adapter One1-2 adapter Connect Perform the procedure below to connect the Heat Exchangers to the machine. adapters 1. Connect a 2-1 adapter (x) to the left return plumbing rack (LR). 2.
  • Page 95 E 3000 Accessories HX 50 HX 50 HX 50 wc_gr008559 ghi_tx001162gb.fm...

  • Page 96: Connecting Two Hx 50 Heat Exchangers

    Accessories E 3000 5.11 Connecting Two HX 50 Heat Exchangers Requirements Machine stopped Two HX 50 Heat Exchangers Connect the 1. Position the Heat Exchangers (a and b) within the space to be heated. HX hoses 2. Connect Heat Exchanger (a) to left accessory supply (LS). 3.
  • Page 97 E 3000 Accessories HX 50 HX 50 wc_gr008560 ghi_tx001162gb.fm...

  • Page 98: Connecting One Hx 50 Heat Exchanger

    Accessories E 3000 5.12 Connecting One HX 50 Heat Exchanger Requirements Machine stopped One HX 50 Heat Exchanger Connect the 1. Position the Heat Exchanger (a) within the space to be heated. HX hoses 2. Connect Heat Exchanger to left accessory supply (LS). 3.
  • Page 99 E 3000 Accessories HX 50 wc_gr008561 ghi_tx001162gb.fm...

  • Page 100: Connecting Three Hx 100 Heat Exchangers

    Accessories E 3000 5.13 Connecting Three HX 100 Heat Exchangers Requirements Machine stopped Three HX 100 Heat Exchangers One 2-1 adapter One Single Pump Pack (SPP) Auxiliary Pump Pack (APP) (See topic Mounting the Auxiliary Pump Panel.) Connect Perform the procedure below to connect the Heat Exchangers to the machine. adapter 1.
  • Page 101 E 3000 Accessories HX 100 HX 100 HX 100 wc_gr008580 ghi_tx001162gb.fm...

  • Page 102: Connecting Two Hx 100 Heat Exchangers

    Accessories E 3000 5.14 Connecting Two HX 100 Heat Exchangers Requirements Machine stopped Two HX 100 Heat Exchangers Connect the 1. Position the Heat Exchangers (a and b) within the space to be heated. HX hoses 2. Connect Heat Exchanger (a) to left accessory supply (LS). 3.
  • Page 103 E 3000 Accessories HX 100 HX 100 wc_gr008582 ghi_tx001162gb.fm...

  • Page 104: Connecting One Hx 100 Heat Exchanger

    Accessories E 3000 5.15 Connecting One HX 100 Heat Exchanger Requirements Machine stopped One HX 100 Heat Exchangers Connect the 1. Position the Heat Exchanger (a) within the space to be heated. HX hoses 2. Connect Heat Exchanger (a) to left accessory supply (LS). 3.
  • Page 105 E 3000 Accessories HX 100 wc_gr008583 ghi_tx001162gb.fm...

  • Page 106: Connecting Two Hx 200 Heat Exchangers

    Accessories E 3000 5.16 Connecting Two HX 200 Heat Exchangers Requirements Machine stopped Two HX 200 Heat Exchangers One 2-1 adapter One Dual Pump Pack (DPP) Auxiliary Pump Pack (APP) (See topic Mounting the Auxiliary Pump Panel.) Connect the 1. Position the Heat Exchangers (a and b) within the space to be heated. HX hoses 2.
  • Page 107 E 3000 Accessories HX 200 HX 200 wc_gr008584 ghi_tx001162gb.fm...

  • Page 108: Connecting One Hx 200 Heat Exchanger

    Accessories E 3000 5.17 Connecting One HX 200 Heat Exchanger Requirements Machine stopped One HX 200 Heat Exchanger Connect the 1. Position the Heat Exchangers (a) within the space to be heated. HX hoses 2. Connect Heat Exchanger (a) to left accessory supply (LS). 3.

  • Page 109: Burner Setup-Oil

    E 3000 Burner Setup—Oil Burner Setup—Oil Factory Settings Firing rate Fuel pressure Air band Head Nozzle size L/hr (gph) bar (psi) setting shutter F220 10.4 (2.75) 2.25 80° B 10.3 (150) Setting up the Burner Background The burner consists of several different components and subsystems. Each of these components or subsystems must be operating correctly for the burner to function properly.
  • Page 110 Burner Setup—Oil E 3000 Continued from the previous page. When Adjust the burner: Before operating the machine at elevations 305 m (1,000 ft) above or below the location of the previous adjustments 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.
  • Page 111 E 3000 Burner Setup—Oil Continued from the previous page. 9. Analyze the combustion. Follow the combustion analyzer manufacturer’s instructions and the general 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: content: 4–6%...

  • Page 112: Setting/Checking The Electrodes

    Burner Setup—Oil E 3000 Setting/Checking the Electrodes Requirements Power supplies disconnected Ruler/measuring device Procedure Follow the procedure below to check the electrodes. 1. Disconnect the power supplies. 2. Remove the copper fuel line (a) between the fuel pump and the burner housing. 3.
  • Page 113 E 3000 Burner Setup—Oil Continued from the previous page. 7. Use the measurements below to properly set the electrodes. Ref. Description Gap distance Electrode tip to electrode tip 5/32 in. (4 mm) Nozzle center to electrode tip 5/16 in. (7.5 mm) Nozzle end to electrode tip end 1/16 in.

  • Page 114: Replacing The Burner Nozzle

    Burner Setup—Oil E 3000 Replacing the Burner Nozzle Requirements Power supplies disconnected Machine cool Procedure Follow the procedure below to replace the burner nozzle. 1. Disconnect the power supplies. 2. Remove the copper fuel line (a) between the fuel pump and the burner housing. 3.
  • Page 115 E 3000 Burner Setup—Oil Continued from the previous page. 7. Unscrew the burner nozzle (f) from the burner tube. wc_gr008598 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.

  • Page 116: Setting The "Z" Distance

    Burner Setup—Oil E 3000 Setting the “Z” Distance Prerequisites Burner removed from the machine Beckett T501 gauge Procedure Follow the procedure below to set the “Z” distance on F220 heads. 1. Remove the burner from the machine. 2. Loosen the knurled nut 3.
  • Page 117 E 3000 Burner Setup—Oil Continued from the previous page. Measuring Measuring the “Z” distance. a. Place a straight edge over the end of the flame retention head. b. Adjust the 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).

  • Page 118: Adjusting The Air Settings

    Burner Setup—Oil E 3000 Adjusting the Air Settings Factory Air band: 0 settings Air shutter: 6.5 Note: These settings are initial settings only. Adjust the air settings as necessary to obtain the proper smoke spot and combustion analysis values. Background There are two parts to adjusting the air setting: 1) air band;...

  • Page 119: Adjusting The Fuel Pressure

    E 3000 Burner Setup—Oil Adjusting the Fuel Pressure Factory “F” head: 150 psig (10.0 bar) setting Procedure Follow the procedure below to check and adjust the fuel pressure. 1. Shut down the machine. 2. Remove the bleeder valve (a) from the fuel pump. 3.

  • Page 120: Burner Setup-Gas

    Burner Setup—Gas E 3000 Burner Setup—Gas Factory Settings Make sure you 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 Air damper setting Combustion head setting Gas manifold pressure (in.

  • Page 121: Restrictions For Connecting The Gas Supply

    E 3000 Burner Setup—Gas Restrictions for Connecting the Gas Supply Requirements The technician installing the supply gas shall 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. Restrictions The supply gas regulator (a) shall not be installed inside the machine enclosure.

  • Page 122: Setting Up The Burner

    Burner Setup—Gas E 3000 Setting up the Burner Background The burner consists of several different components and subsystems. Each of these components or subsystems must be operating correctly for the burner to function properly. Tools required The following tools are required to adjust the burner: High-quality combustion analyzer Smoke spot tester Manometer...
  • Page 123 E 3000 Burner Setup—Gas Continued from the previous page. 9. Conduct a smoke spot test. Follow the smoke spot tester 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).

  • Page 124: Removing And Installing The Combustion Head

    Burner Setup—Gas E 3000 Removing and Installing the Combustion Head Requirements Machine shut down Burner cool Removal Perform the procedure below to remove the combustion head. 1. Open the access door and locate the burner. 2. Remove the burner assembly cover (a). wc_gr008977 wc_gr008960 3.
  • Page 125 E 3000 Burner Setup—Gas Continued from the previous page. 6. Remove the combustion head (f). wc_gr008962 wc_gr008963 Installation Perform the procedure below to install the combustion head. 1. Install the combustion head into the burner. Adjust the combustion per topic Adjusting the Combustion Head.

  • Page 126: Adjusting The Ionization Probe And The Electrode

    Burner Setup—Gas E 3000 Adjusting the Ionization Probe and the Electrode Requirements Machine shut down Burner cool Procedure Perform the procedure below to adjust both the ionizaton probe and the electrode. 1. Shut down the machine and allow it to cool. 2.

  • Page 127: Changing The Burner Diaphragm

    E 3000 Burner Setup—Gas Changing the Burner Diaphragm Requirements Machine shut down Machine cool Correct burner diaphragm: C6 for NG; C3 for LP Background The burner can burn either LP or Natural Gas (NG). The burner comes from the factory set up to burn NG. In order to burn LP (or to switch back from LP to NG), the burner diaphram must be changed.

  • Page 128: Checking And Adjusting The Air Damper (Gate) Setting

    Burner Setup—Gas E 3000 Checking and Adjusting the Air Damper (Gate) Setting Requirements Machine shut down Burner cool Procedure Follow the procedure below to check the air damper setting. Note: This procedure must be performed at each new job site. The proper setting depends on environmental conditions at the job site.

  • Page 129: Adjusting The Combustion Head

    E 3000 Burner Setup—Gas Adjusting the Combustion Head Requirements Machine shut down Machine cool Procedure Perform the procedure below to adjust the combustion head. 1. Open the access door and locate the burner. 2. Remove the burner assembly cover (a). wc_gr008977 wc_gr008960 3.

  • Page 130: Checking The Supply Gas Pressure

    Burner Setup—Gas E 3000 Checking the Supply Gas Pressure Requirements Machine shut down Supply gas turned off Manometer Nipple Checking Perform the procedure below to check and adjust the supply gas pressure. pressure 1. Shut down the machine and allow it to cool. 2.
  • Page 131 E 3000 Burner Setup—Gas Continued from the previous page. 7. Check the pressure reading on the manometer. 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.

  • Page 132: Checking And Adjusting The Burner Gas Pressure

    Burner Setup—Gas E 3000 7.10 Checking and Adjusting the Burner Gas Pressure Requirements Machine shut down Adequate supply gas pressure Manometer Checking Follow the procedure below to check and adjust the burner gas pressure. pressure 1. Turn the control knob (a) to the “OFF” position. wc_gr009000 wc_gr008997 2.
  • Page 133 E 3000 Burner Setup—Gas Continued from the previous page. Adjusting Follow the procedure below to adjust the burner gas pressure at the gas control pressure valve. 1. Remove the cap (e). wc_gr008999 2. Turn the screw under the cap to adjust the burner gas pressure: clockwise to increase pressure, counterclockwise to decrease pressure.

  • Page 134: Maintenance

    Maintenance E 3000 Maintenance Periodic Maintenance Schedule The table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment. Interval* (hours of service) Daily 2 Week Yearly...

  • Page 135: Inspecting The Htf System And The Fuel System

    E 3000 Maintenance Inspecting the HTF System and the Fuel System Requirements Machine shut down Burner cool HTF System Hoses: 1. Rotate the hose reel brake T-handle counterclockwise to release the brake. 2. Unwind all the hose off the reel. Inspect the hose for leaks and/or damage. 3.

  • Page 136: Repairing A Hose

    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.
  • Page 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. wc_tx001803gb.fm...

  • Page 138: Inspecting The Electrical Components

    Maintenance E 3000 Inspecting the Electrical Components Requirements Machine shut down and cooled Circuit breaker off Power disconnected WARNING Electric shock hazard. High voltage exists at various locations in the machine. High voltage can cause severe injury or death. Disconnect the power supplies before inspecting the electrical systems. Inspections Inspect the electrical connections and cables on the following items for corrosion, wear, or damage.
  • Page 139 E 3000 Maintenance Continued from the previous page. Item Reference Photo Hose reel rewind motor Light Trailer Lights Wiring harness Brake Generator (if applicable) Low-level shut- down device Thermocouple wc_tx001803gb.fm...

  • Page 140: Filling The Htf Reservoir

    Maintenance E 3000 Filling the HTF Reservoir Requirements Genuine Wacker Neuson Heat Transfer Fluid, or Dowfrost HD 50 Heat Transfer Fluid Machine is on a level surface NOTICE: Use only factory-recommended Heat Transfer Fluid (HTF). Failure to comply may damage the machine.
  • Page 141 E 3000 Maintenance Continued from the previous page. 7. Open valve #6 (right hose reel supply valve). 8. Move the right pump switch (b) to the ON position and watch the HTF reservoir sightglass (c), then move the right pump switch to the OFF position when the level is between the minimum and maximum marks on the sightglass.

  • Page 142: Cleaning The Htf Strainer

    Maintenance E 3000 Cleaning the HTF Strainer Requirements Machine shut down Source of clean, warm water Removal Perform the procedure below to clean the HTF strainer. 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.
  • Page 143 E 3000 Maintenance Continued from the previous page. Installation 1. Inspect the strainer gasket (f) and 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.

  • Page 144: Replacing The Fuel Filter

    Maintenance E 3000 Replacing the Fuel Filter Requirements Machine shut down New fuel filter element and gasket kit Removal Perform the procedure below to remove the fuel filter element. Note: In the interests of environmental protection, place a plastic sheet and a container under the burner to collect any liquid which drains off.

  • Page 145: Lubricating The Hose Reel System

    E 3000 Maintenance Lubricating the Hose Reel System Requirements Machine shut down Machine cool Procedure 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: Cleaning The Turbulators And The Exhaust Ducting

    Maintenance E 3000 Cleaning the Turbulators and the Exhaust Ducting Requirements Machine shut down Machine cool Procedure Follow the procedure below to clean/change the turbulator tubes. 1. Allow the machine to cool. WARNING Burn hazard. The hydronic heater is very hot when the machine is operating. When hot it can cause severe burns.
  • Page 147 E 3000 Maintenance Continued from the previous page. 7. Vacuum out each burner tube. 8. Remove the exhaust stack (e) (both inner and outer panels). wc_gr008604 9. Vacuum out the exhaust ducting (f) and the heater. 10.Reinstall the exhaust stack. 11.Reassemble the machine.

  • Page 148: Inspecting/Replacing The Rope Gasket

    Maintenance E 3000 8.10 Inspecting/Replacing the Rope Gasket Requirements Machine shut down Machine cool Integrity Follow the procedure below to confirm the integrity of the flue box rope gasket. inspection 1. Allow the machine to cool. WARNING Burn hazard. The hydronic heater is very hot when the machine is operating. When hot it can cause severe burns.

  • Page 149: Removing The Oil Burner

    E 3000 Maintenance 8.11 Removing the Oil Burner Requirements Power supplies disconnected Machine cool Procedure Follow the procedure below to remove the burner. 1. Disconnect the power supplies. 2. Disconnect fuel lines (a) at the quick-connects. 3. Remove the burner controller (b) to expose the wiring. Label all the wires to assist in reconnecting.

  • Page 150: Installing The Burner

    Maintenance E 3000 8.12 Installing the Burner Requirements Power supplies disconnected Machine cool Procedure Follow the procedure below to install the burner. 1. Position the burner inside the machine and secure it to the hydronic heater. wc_gr008595 2. Reconnect the wiring from the snap switch cable (c) and burner cable (d) to the burner controller.

  • Page 151: Storing The Machine

    E 3000 Maintenance 8.13 Storing the Machine Short-term 1. Fill the HTF reservoir if it is low. storage 2. Stop the machine. See topic Shutting Down and Packing Up the Machine. 3. Remove and store any accessories. 4. Allow the heater to cool sufficiently. 5.

  • Page 152: Storing The Genset

    Maintenance E 3000 8.14 Storing the Genset Short term If the genset sits idle for more than one month, exercise the genset at least two hours each month by running the genset at approximately 1/2 rate power. A single two-hour exercise period is preferred over several shorter periods. Long term If the genset is to be idle for more than 120 days: 1.

  • Page 153: Preparing The Machine For Seasonal Operation

    E 3000 Maintenance 8.15 Preparing the Machine for Seasonal Operation Background After removing the machine from long-term storage, it must be prepared for operation. Perform the procedures below before each seasonal use. Before Perform the procedures below before you power up the machine. powering up machine Item...

  • Page 154: Connecting And Maintaining The Battery

    Maintenance E 3000 8.16 Connecting and Maintaining the Battery WARNING Explosion hazard. Batteries can emit explosive hydrogen gas. Keep all sparks and flames away from the battery. Do not short-circuit battery posts. WARNING Battery fluid is poisonous and corrosive. In the event of ingestion or contact with skin or eyes, seek medical attention immediately.

  • Page 155: Genset Maintenance

    Onan Genset Genset Maintenance Genset Maintenance Periodic Maintenance Schedule The table below lists basic machine maintenance. Tasks designated with check marks may be performed by the operator. Tasks designated with square bullet points require special training and equipment. Interval* (hours of service) Every 2 Daily Monthly...

  • Page 156: Checking The Engine Oil

    Genset Maintenance Onan Genset Checking the Engine Oil Requirements Genset stopped Machine level Checking Perform the procedure below to check the engine oil. WARNING Burn hazard. Crankcase pressure can blow hot oil out of the fill opening causing severe burns. Stop the genset before removing the dipstick/plug.

  • Page 157: Changing The Engine Oil And Oil Filter

    Onan Genset Genset Maintenance Changing the Engine Oil and Oil Filter Requirements Engine warm New oil filter Fresh, clean oil wc_gr008138 Draining oil Perform the procedure below to change the oil and oil filter. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid which drains off.
  • Page 158 Genset Maintenance Onan Genset Continued from the previous page. 7. Unscrew the oil filter (c) and remove it through the front access opening. wc_gr008035 8. Clean the oil filter mounting surface of the engine. Filling 1. Apply a thin coat of clean oil to the gasket of the new oil filter. 2.

  • Page 159: Checking The Engine Coolant Level

    Onan Genset Genset Maintenance Checking the Engine Coolant Level Requirements Genset stopped Engine cool Checking Perform the procedure below to check the engine coolant level. WARNING Personal injury hazard. Contact with moving parts and hot exhaust can cause severe injury. Do not run the genset with the access covers removed.

  • Page 160: Replacing The Air Filter Element

    Genset Maintenance Onan Genset Replacing the Air Filter Element Requirements Engine stopped New air filter element Removing Perform the procedure below to replace the air filter element. 1. Disconnect the battery. 2. Remove the front access cover (a). wc_gr008038 3. Remove the wing nuts (b), bracket (c), filter housing (d), and the filter element (e).

  • Page 161: Replacing Engine Fuel Filter

    Onan Genset Genset Maintenance Replacing Engine Fuel Filter Requirements Genset shut down and cool New fuel filter WARNING Fire hazard. Diesel fuel can ignite and cause severe burns. Keep a type ABC fire extinguisher (or equivalent) at hand when performing this procedure.
  • Page 162 Genset Maintenance Onan Genset Continued from the previous page. 2. Loosely secure the filter and filter bracket (f) to the generator with the two filter bracket mounting screws (e) and reconnect the fuel lines (a and b). Note: Take care not to cross-thread the fuel fittings. Thread them in by hand and tighten one flat past seating.

  • Page 163: Changing Engine Coolant

    Onan Genset Genset Maintenance Changing Engine Coolant Requirements Genset shut down and cool 50/50 mixture of ethylene glycol and water Collection container, 2-liter (1/2-gal) Funnel Background The genset is filled with a 50/50 mixture of ethylene glycol and water at the factory. This formula is suitable for temperatures as low as -37°C (-34°F).
  • Page 164 Genset Maintenance Onan Genset Continued from the previous page. 5. Remove bottom access cover. 6. Position the collection container under the drain cock (b). wc_gr008039 7. Open the drain cock and drain the coolant. Approximately 1.5 L (1.5 qts.) will drain.

  • Page 165: Genset Shut-Down Codes

    Onan Genset Genset Maintenance Genset Shut-Down Codes Background The genset controller includes built-in diagnostic capabilities. Through the blinking of the light indicator on the control switch, a genset fault may be diagnosed. After a fault shutdown, the indicator light will blink a code that indicates the type of fault. wc_gr007811 The indcator light will repeatly blink 1, 2, 3, or 4 blinks at a time.
  • Page 166 Genset Maintenance Onan Genset Code Fault Type Corrective Action High temperature fault 1. Check engine coolant level and add coolant First-level fault; engine coolant temperature as necessary. exceeded 110°C (230°F). 2. Check for and remove any objects blocking the air inlet or outlet openings in the bottom and sides of the genset.
  • Page 167 Onan Genset Genset Maintenance Code Fault Type Corrective Action Governor overload fault 1. Disconnect any extra loads. The duration of operation at or near full-duty 2. Check for and repair fuel leaks. Air in the fuel cycle was beyond the design limit. supply can disrupt frequency.
  • Page 168 Genset Maintenance Onan Genset Code Fault Type Corrective Action Over-prime fault 1. Check control switch. Remove anything that may be holding it in the Prime position. Prime mode exceeded 3 minutes. wc_tx002068gb.fm...

  • Page 169: 10 Troubleshooting

    E 3000 Troubleshooting 10 Troubleshooting 10.1 Troubleshooting the Machine Problem / Symptom Reason Remedy Thaw progress is below The insulation is insuffi- Add additional insulation capacity. cient. blankets. The moisture is insufficient. Verify that there is standing water on job site. There is no vapor barrier.
  • Page 170 Troubleshooting E 3000 Problem / Symptom Reason Remedy Pump is noisy and HTF flow The suction valve is not fully Verify that the suction valve is below nominal value. open. is fully open. The HTF temperature is Warm the HTF and hoses below -26°C (-15°F).

  • Page 171: Troubleshooting The Oil Burner

    E 3000 Troubleshooting 10.2 Troubleshooting the Oil Burner Problem / Symptom Reason Remedy The burner does not start. Improper switch position or Verify that the breaker is protective function action. ON. Verify that the HTF level is within range and low level shutdown device is reset (low level indicator light must be OFF).

  • Page 172: Troubleshooting The Gas Burner

    Troubleshooting E 3000 10.3 Troubleshooting the Gas Burner Problem / Symptom Reason Remedy The flame ignites, but the The phase/neutral lines are Correct the wiring. burner goes to lockout reversed. within 5 seconds The wiring to ground is Correct the wiring. faulty.

  • Page 173: Technical Data

    E 3000 Technical Data 11 Technical Data 11.1 Machine Model Item No. Item No. Item No. Item No. Units E 3000 0620158 0620219 0620678 0620679 Weight (no fuel) 2,531 2,769 2,928 3,209 kg (lb) (5,580) (6,105) (6,457) (7,073) Weight (full fuel) 3,262 3,500 3,613...

  • Page 174: Trailer

    Technical Data E 3000 11.2 Trailer Item Number 0620158 0620219 0620678 0620679 Model E 3000 E 3000 E 3000 E 3000 GAWR 1,588 2,359 (Gross Axle Weight Rating) (lb) (3,500) (5,200) Wheel diameter (in.) (14) (15) Tire code — 225 75R14 215 75R15 Tire pressure (psi)

  • Page 175: Msds: Dowfrost™ Hd 50

    MSDS: Dowfrost™ HD 50 MSDS: Dowfrost HD 50 Material Safety Data Sheet The Dow Chemical Company Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Print Date: 18 Aug 2011 The Dow Chemical Company encourages and expects you to read and understand the entire (M)SDS, as there is important information throughout the document.
  • Page 176 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Inhalation: At room temperature, exposure to vapor is minimal due to low volatility. Mist may cause irritation of upper respiratory tract (nose and throat). Ingestion: Very low toxicity if swallowed.
  • Page 177 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Personal Precautions: Keep unnecessary and unprotected personnel from entering the area. Use appropriate safety equipment. For additional information, refer to Section 8, Exposure Controls and Personal Protection.
  • Page 178 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Physical and Chemical Properties Liquid. Physical State Yellow to green Color Characteristic Odor No test data available Odor Threshold Not applicable, Water boils off Flash Point - Closed Cup Not applicable to liquids Flammability (solid, gas)
  • Page 179 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Eye damage/eye irritation May cause slight temporary eye irritation. Corneal injury is unlikely. Skin corrosion/irritation Prolonged contact is essentially nonirritating to skin. Repeated contact may cause flaking and softening of skin.
  • Page 180 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 Transport Information DOT Non-Bulk NOT REGULATED DOT Bulk NOT REGULATED IMDG NOT REGULATED ICAO/IATA NOT REGULATED This information is not intended to convey all specific regulatory or operational requirements/information relating to this product.
  • Page 181 MSDS: Dowfrost™ HD 50 Product Name: DOWFROST* HD 50 Heat Transfer Fluid, Dyed Issue Date: 09/24/2010 All components of this product are on the TSCA Inventory or are exempt from TSCA Inventory requirements under 40 CFR 720.30 CEPA - Domestic Substances List (DSL) This product contains one or more substances which are not listed on the Canadian Domestic Substances List (DSL).
  • Page 182 MSDS: Dowfrost™ HD 50...

  • Page 183: Fuji Temperature Controller

    Fuji Temperature Controller Fuji Temperature Controller Fuji Temperature Controller Hysteresis (differential) Adjusting wc_tx001673gb.fm...
  • Page 184 Fuji Temperature Controller Fuji Temperature Controller Low Temperature Limit Adjusting wc_tx001673gb.fm...
  • Page 185 Fuji Temperature Controller Fuji Temperature Controller High Temperature Limit Adjusting wc_tx001673gb.fm...
  • Page 186 Fuji Temperature Controller wc_tx001673gb.fm...

  • Page 187: Tire Safety Information

    Tire Safety Information Tire Safety Information Introduction to Tire Safety Information Federal Regulation 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 Tire Safety Information 1. T AFETY NFORMATION This portion of the - Trailer . Section 1.1 contains Tow Vehicle . Section 1.2 contains Section 1.3 contains a Glossary of Tire Terminology -technical terms. Section 1.4 contains information from the NHTSA brochure entitled “Tire Safety – Everything Rides On It”. This brochure This brochure, as well as the preceding subsections, describes the following items;...
  • Page 189 Tire Safety Information Excessive loads and/or underinflation cause tire overloading and, as a result, abnormal tire flexing occurs. This situation can generate an excessive amount of heat within the tire. Excessive heat may lead to tire failure. It is the air pressure that enables a tire to support the load, so proper inflation is critical.
  • Page 190 Tire Safety Information Bead The part of the tire that is made of steel wires, wrapped or reinforced by ply cords and that is shaped to fit the rim. Bead separation This is the breakdown of the bond between components in the bead. Bias ply tire A pneumatic tire in which the ply cords that extend to the beads are laid at alternate angles substantially less than 90 degrees to the centerline of the tread.
  • Page 191 Tire Safety Information Intended outboard sidewall The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle.
  • Page 192 Tire Safety Information A layer of rubber-coated parallel cords. Ply separation A parting of rubber compound between adjacent plies. Pneumatic tire A mechanical device made of rubber, chemicals, fabric and steel or other materials, that, when mounted on an automotive wheel, provides the traction and contains the gas or fluid that sustains the load. Production options weight The combined weight of those installed regular production options weighing over 2.3 kilograms (5 lbs.) in excess of those standard items which they replace, not previously considered in curb weight or accessory...
  • Page 193 Tire Safety Information Tread rib A tread section running circumferentially around a tire. Tread separation Pulling away of the tread from the tire carcass. Treadwear indicators (TWI) The projections within the principal grooves designed to give a visual indication of the degrees of wear of the tread.
  • Page 194 Tire Safety Information Use this information to make tire safety a regular part of your vehicle maintenance routine. Recognize that the time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire failure.
  • Page 195 Tire Safety Information 1.5.4. S TEPS FOR AINTAINING ROPER RESSURE Step 1: Locate the recommended tire pressure on the vehicle's tire information placard, certification label, or in the owner's manual. Step 2: Record the tire pressure of all tires. Step 3: If the tire pressure is too high in any of the tires, slowly release air by gently pressing on the tire valve stem with the edge of your tire gauge until you get to the correct pressure.
  • Page 196 Tire Safety Information 1.5.9.1. Information on Passenger Vehicle Tires Please refer to the diagram below. The "P" indicates the tire is for passenger vehicles. Next number This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In general, the larger the number, the wider the tire.
  • Page 197 Tire Safety Information Letter Rating Speed Rating 99 mph 106 mph 112 mph 118 mph 124 mph 130 mph 149 mph 168* mph 186* mph * For tires with a maximum speed capability over 149 mph, tire manufacturers sometimes use the letters ZR. For those with a maximum speed capability over 186 mph, tire manufacturers always use the letters ZR.
  • Page 198 Tire Safety Information Please refer to the following diagram. Tires for light trucks have other markings besides those found on the sidewalls of passenger tires. The "LT" indicates the tire is for light trucks or trailers. An "ST" is an indication the tire is for trailer use only. Max.
  • Page 199 Tire Safety Information...

  • Page 200: Schematics

    Schematics E 3000 12 Schematics 12.1 Composite Schematic—Machine with Oil Burner wc_tx001952gb.fm...

  • Page 201: Composite Schematic-Machine With Gas Burner

    E 3000 Schematics 12.2 Composite Schematic—Machine with Gas Burner wc_tx001952gb.fm...

  • Page 202: Electrical Schematic Components

    Schematics E 3000 12.3 Electrical Schematic Components Use the following table of symbols for the schematics found throughout this chapter. Symbol Description Circuit breaker 1 GFCI 1 Ground Fault Circuit Interrupt 1 Fuse 1 HOSE Hose rewind ON/OFF switch REWIND Rewind motor RT (right) pump Left pump...
  • Page 203 E 3000 Schematics Symbol Description Relay normally closed contacts (K2) Relay normally open contacts (K2) Fuse 3 LOW LEVEL Low-level shut-down device power connection terminals Relay coil (K1) Relay normally open contacts (K1) Relay normally closed contacts (K1) Pilot light 1 Low level fault Pilot light 2 Burner fault...
  • Page 204 Schematics E 3000 Symbol Description Thermal switch 1 (snap disc) HTR1 Heater (fuel prewarmer) Cad cell LOW LEVEL Low-level shut-down device OVERRIDE momentary override ON/OFF switch. MOMENTARY E-STOP Emergency stop switch E-STOP Relay coil (K4) Relay normally closed contacts (K4) Relay normally open contacts (K1) Fuse 4 JJN-50...

  • Page 205: Circulation System Circuit

    E 3000 Schematics 12.4 Circulation System Circuit wc_tx001952gb.fm...

  • Page 206: Rewind System Circuit

    Schematics E 3000 12.5 Rewind System Circuit wc_tx001952gb.fm...

  • Page 207: Gas Train Schematic

    E 3000 Schematics 12.6 Gas Train Schematic wc_tx001952gb.fm...

  • Page 208: Generator

    Schematics E 3000 12.7 Generator wc_tx001952gb.fm...

  • Page 209: Trailer Plug - Wiring Diagram

    E 3000 Schematics 12.8 Trailer Plug — Wiring Diagram Trailer plug The slots on the trailer plug receptacle are each designated for specific components. The designations are as follows. Designation Wire color Battery (+12V) Black Running lights Green Left hand turn/stop Ground White Electric brake...

  • Page 210: Trailer Junction Box - Wiring Diagram

    Schematics E 3000 12.9 Trailer Junction Box — Wiring Diagram The wires inside the trailer junction box are designated 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.

  • Page 211: 12.10 Trailer Lights And Brakes - Wiring Diagram

    E 3000 Schematics 12.10 Trailer Lights and Brakes — Wiring Diagram wc_gr008465 wc_tx001952gb.fm...

  • Page 212: 12.11 Trailer Lights And Brakes - Components

    Schematics E 3000 12.11 Trailer Lights and Brakes — Components Description Description Right side light, amber Left side light, amber Right side miniature light, amber Left side miniature light, amber Right side fender light, amber Left side fender light, amber Right rear fender light, red Left rear fender light, red Right side stop and tail light...
  • Page 214 Wacker Neuson Production Americas LLC, N92W15000 Anthony Ave., Menomonee Falls, WI. 53051 Tel.: (262) 255-0500 Fax: (262) 255-0550 Tel.: (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong. Tel: (852) 3605 5360, Fax: (852) 2758 0032...

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