Generac Power Systems MAC400HC Owner's Manual
MAC400FHC
004390
Flameless Heat Cart
Owner’s Manual
MODEL NUMBER: _________________________
SERIAL NUMBER: _________________________
DATE PURCHASED:________________________
SAVE THIS MANUAL FOR FUTURE REFERENCE
WARNING
CANCER AND REPRODUCTIVE HARM
www.P65Warnings.ca.gov.
(000393a)
ii Owner’s Manual for Flameless Heat Cart
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 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
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
Owner’s Manual for Flameless Heat Cart iii
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iv Owner’s Manual for Flameless Heat Cart
Section 1: Introduction and Safety
(000100a)
WARNING
Consult Manual. Read and understand manual
completely before using product. Failure to
completely understand manual and product
could result in death or serious injury.
(000001)
DANGER
Indicates a hazardous situation which, if not avoided,
will result in death or serious injury.
(000002)
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
(000003)
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Introduction and Safety
Introduction
Thank you for purchasing a Generac Mobile Products,
LLC product. This unit has been designed to provide
high-performance, efficient operation, and years of quality use when maintained properly.
The MAC400FHC flameless heat cart is designed and
built for sustained, reliable heat production in industrial
operating conditions and environments. The
MAC400FHC is built to withstand frequent handling
under these conditions.
The unit has forklift access and chain attach points on
both sides. The fully enclosed design protects the operating components, allowing all-weather storage and operations.
The information in this manual is accurate based on
products produced at the time of publication. The manufacturer reserves the right to make technical updates,
corrections, and product revisions at any time without
notice.
Read This Manual Thoroughly
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 particular operation that may be hazardous if performed incorrectly or carelessly. Observe
them carefully. Alert definitions are as follows:
If any section of the manual is not understood, contact
your nearest Generac Mobile Products (GMP) Authorized Service Dealer (ASD), or contact Generac Mobile
Products Customer Service at 800-926-7968, or visit
http://www.generacmobileproducts.com with any ques-
tions or concerns.
The owner is responsible for proper maintenance and
safe use of the equipment.
SAVE THESE INSTRUCTIONS for future reference. This
manual contains important instructions for the unit that
should be followed during installation, operation, and
maintenance of the heater and batteries. ALWAYS supply
this manual to any individual that will use the unit.
Safety Rules
The manufacturer cannot anticipate every possible circumstance that might involve a hazard. The alerts in this
manual, and on tags and decals affixed to the unit, are
not all-inclusive. If using a procedure, work method, or
operating technique that the manufacturer does not specifically recommend, verify that it is safe for others and
does not render the equipment unsafe.
Owner’s Manual for Flameless Heat Cart 1
NOTE: Notes contain additional information important to
a procedure and will be found within the regular text of
this manual.
These safety alerts cannot eliminate the hazards that
they indicate. Common sense and strict compliance with
the special instructions while performing the action or
service are essential to preventing accidents.
How to Obtain Service
When the unit requires servicing or repairs, contact a
GMP ASD for assistance. Service technicians are factory-trained and are capable of handling all service
needs. Go to https://www.generacmobileproducts.com/
parts-service/find-service for assistance locating a
dealer.
When contacting a GMP ASD about parts and service,
always supply the complete model and serial number of
the unit as given on its data decal located on the unit.
Record the model and serial numbers in the spaces provided on the inside front cover of this manual.
Introduction and Safety
Asphyxiation. Running engines produce
carbon monoxide, a colorless, odorless,
poisonous gas. Carbon monoxide, if not
avoided, will result in death or serious injury.
(000103)
DANGER
DANGER
(000239)
Hydraulic Fluid Injection. High-pressure, high-temperature
hydraulic fluid can pierce skin and cause severe burns. Do not
check for leaks with hands. Seek immediate medical attention in case of
accident. Failure to protect body accordingly will result in death or serious
injury.
(000107)
WARNING
Hearing Loss. Hearing protection is
recommended when using this machine.
Failure to wear hearing protection could
result in permanant hearing loss.
(000111)
WARNING
Moving Parts. Keep clothing, hair, and
appendages away from moving parts. Failure
to do so could result in death or serious injury.
(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.
(000377)
WARNING
Vision loss. Eye protection is required when
servicing unit. Failure to do so could result in
vision loss or serious injury.
CAUTION
(000229)
Equipment 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 will result in
equipment damage.
(000105)
DANGER
Explosion and Fire. Fuel and vapors are
extremely flammable and explosive. Add fuel
in a well ventilated area. Keep fire and spark
away. Failure to do so will result in death
or serious injury.
(000143)
DANGER
Explosion and Fire. Fuel and vapors are extremely
flammable and explosive. Store fuel in a well
ventilated area. Keep fire and spark away. Failure
to do so will result in death or serious injury.
(000214)
DANGER
Explosion and Fire. Do not fill fuel tank past full line.
Allow for fuel expansion. Overfilling may cause fuel
to spill onto engine causing fire or explosion, which
will result in death or serious injury.
(000147)
WARNING
Risk of Fire. Unit must be positioned in a
manner that prevents combustible material
accumulation underneath. Failure to do so
could result in death or serious injury.
WARNING
Fire risk. Fuel and vapors are extremely
flammable. Do not operate indoors. Doing so
could result in death, serious injury, or
property or equipment damage.
(000281)
General Hazards
Explosion and Fire Hazards
2 Owner’s Manual for Flameless Heat Cart
Towing Hazar ds
WARNING
Explosion and fire risk. Do not smoke near unit.
Keep fire and spark away. Failure to do so could
result in death, serious injury, or property or
equipment damage.
(000282)
WARNING
Crushing hazard. Verify parking brake is properly
secured and unit is on level ground. An unsecured
unit could suddenly roll or move, and could result in
death, serious injury, or equipment damage.
(000352)
WARNING
Property or Equipment Damage. Tighten wheel lug
nuts every 30 days to factory specifications. Failure 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
Explosion. Batteries emit explosive gases while charging.
Keep fire and spark away. Wear protective gear when
working with batteries. Failure to do so could result in
death or serious injury.
(000162)
WARNING
Explosion. Do not dispose of batteries in a fire. Batteries
are explosive. Electrolyte solution can cause burns and
blindness. If electrolyte contacts skin or eyes, flush with water
and seek immediate medical attention.
(000163a)
WARNING
Risk of burn. Do not open or mutilate batteries.
Batteries contain electrolyte solution which can
cause burns and blindness. If electrolyte contacts
skin or eyes, flush with water and seek immediate
medical attention.
(000130)
WARNING
Accidental Start-up. Disconnect the negative battery
cable, then the positive battery cable when working
on unit. Failure to do so could result in death
or serious injury.
WARNING
Environmental Hazard. Always recycle batteries at an
official recycling center in accordance with all local
laws and regulations. Failure to do so could result in
environmental damage, death or serious injury.
(000228)
Introduction and Safety
Battery Hazards
Always recycle batteries in accordance with local laws
and regulations. Contact your local solid waste collection
site or recycling facility to obtain information on local
recycling processes. For more information on battery
recycling, visit the Battery Council International website
at: http://batterycouncil.org
Service Safety
• DO NOT perform even routine service (oil/filter
changes, cleaning, etc.) unless all electrical components are shut down.
• Replace all missing and hard to read decals.
Decals provide important operating instructions
and warn of dangers and hazards.
• Wear all task-appropriate Personal Protective
Equipment (PPE) when completing maintenance
or service tasks.
Owner’s Manual for Flameless Heat Cart 3
Introduction and Safety
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4 Owner’s Manual for Flameless Heat Cart
Section 2: General Information
Specifications
Heater 400,000 BTU/hour (117.2 kW/hour) maximum
Type Flameless
Power Isuzu 4LE2X Tier 4 turbo diesel, 66 HP (49.2 kW)
Operating Speed 2400 rpm
Engine Controls/Display IFM CR0403 / Murphy PV405
General Information
Air Velocity
Battery 950CCA wet cell battery
Static Pressure
Air Outlet 12 in (305 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
3600 CFM (6116 m
9 in H
O (22.8 mm H2O)
2
3
/hour)
Hitch Type Pintle ring
Tire Size 4 in x 8 in (10.2 cm x 20.3 cm)
Lug Nut Torque 100 ft-lbs (135.6 Nm)
Duct Length 25 ft (7.6 m)
Estimated Heater Efficiency 85%
Dimensions 120 in x 54 in x 82 in (3.05 m x 1.37 m x 2.08 m)
Weight 4700 lbs (2131.9 kg) operating weight
Owner’s Manual for Flameless Heat Cart 5
General Information
001918
001920
A
B
C
D
E
F
G
H
J
K L
M
N
P
Q
R
Internal Component Locations
Figure 2-1. Heater Components
A Engine radiator K Diesel oxidation catalyst
B Air filter 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)
6 Owner’s Manual for Flameless Heat Cart
External Component Locations
004395
A
C
B
D
E
F
G
H
C
L
M
I
J
K
General Information
Figure 2-2. External 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
Owner’s Manual for Flameless Heat Cart 7
General Information
(000149)
DANGER
Risk of poisoning. Do not use mouth to siphon
coolant. Doing so will result in death or serious
injury.
(000168)
DANGER
Explosion and Fire. Fuel and vapors are
extremely flammable and explosive. Keep fire
and spark away. Failure to do so will result
in death or serious injury.
(000204)
DANGER
Explosion and Fire. Do not overfill fuel tank.
Overfilling may cause fuel to leak and ignite
or explode, resulting in death or serious injury.
Emissions Information
See the diesel engine manual for more information.
Engine Oil Recommendations
Grade Type
API CE, CE, CF, CF-4, CH-4, CI-4, CI-4 plus
ACEA A3/B3, A3/B4, A5/B5, E2, E3, D4, E5, E7
JASO DH-1
NOTE: Certain brands/types of oil can be used regardless of specified API or ACEA grade.
Change oil and oil filter at least once every 12 months,
even if the hours of operation are fewer than the otherwise recommended service interval. See the diesel
engine manual for recommended oil types.
Selection of Viscosity
The chart below shows appropriate oil types according to
ambient temperature.
recommended to eliminate the need for repeated draining and refilling. Follow these antifreeze/water guidelines:
• A 50/50 ethylene glycol base antifreeze/water mix,
which provides protection to -34 °F (-37 °C), is
recommended for use in this engine.
• Never exceed a 60/40 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 information.
Fuel System
The engine is designed to use either Number 1-D or
Number 2-D diesel fuel.
Figure 2-3. Engine Oil Viscosity Chart
Coolant Recommendations
• Use Number 2-D diesel fuel whenever possible for
better fuel economy.
• Use Number 1-D or a winterized blend at tempera-
tures below 20 °F (-7 °C) (check with the service
station operator to verify the fuel is properly
blended).
The following are required for diesel fuel:
• Must be free from dust particles.
• Must have adequate viscosity.
• Must have high cetane value.
Use of improper coolants can damage the engine cooling
system. Use demineralized or distilled water for best
results. Hard water causes scale deposits, which reduces
cooling efficiency and raises internal temperatures,
possibly leading to engine damage.
The cooling system should be drained after engine operation in areas where the atmospheric temperature falls
below freezing. The use of antifreeze solution is highly
8 Owner’s Manual for Flameless Heat Cart
• Must have high fluidity at low temperature.
• Must have low or ultra-low sulfur (ULSD) content
EPA requirement; varies by geographic location.
• Must have little residual carbon.
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