Generac Power Systems MAC400HC Owner's Manual

MAC400FHC
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
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
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.
Applicable Standard Recommendation
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.
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)
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)
CAUTION
(000313)
Pinching and crushing hazard. To avoid possible injury, keep fingers away from pivot point when folding or unfolding trailer tongue.
JIS (Japanese Industrial Standard) No. 2
DIN (Deutsche Industrie Normen) DIN 51601
SAE (Society of Automotive Engineers) Based on SAE-J-313C
BS (British Standard) Based on BS/2869-1970
Engine performance will be diminished if fuel other than what is specified is used. See the engine manual for more information.
No. 2-D
Class A-1

Hydraulic Oil

General Information
Driving a vehicle with a cart in tow is vastly different than driving the same vehicle without a cart in tow. Consider the following:
It takes longer to get up to speed.
More room is needed to turn.
More distance is needed to stop.
The driver is responsible for keeping the vehicle
and cart in control, and for all damage caused if control is lost.
Before towing, verify the following:
Coupling, tires, wheels, and lights are in working
order.
Wheel lug nuts are tightened to 100 ft-lbs (135.6
Nm).
The unit is not running.
While towing, make regular stops to verify the following:
Coupler is secured to the hitch and locked.
No damage or unusual wear to tire treads or side-
walls.
Cart and doors are latched and secured.
Type: Exxon Mobil DTE-10 ISO VG 68 hydraulic oil.

Cart Towing Guidelines

NOTE: Do not exceed 15 mph (24 km/h).
The front axle is steered by a tow bar with a pintle ring hitch. It is equipped with a mechanical parking brake activated by raising the tow bar to the locked position.
NOTE: See the tow vehicle manual for coupling instruc­tions.

Parking Brake Use

See Figure 2-4. Engage the parking brake by raising the tow bar to the locked position. The locking lever (A) holds the tow bar in place. Do not operate the unit without the parking brake engaged.
Lift the locking lever up and slowly lower the tow bar to disengage the parking brake.
NOTE: Do not attempt to move the unit with the parking brake engaged; equipment damage may occur.
Owner’s Manual for Flameless Heat Cart 9
General Information
A
A
B
C
D
E
F
G
Figure 2-4. Parking Brake Engaged

Controller

For troubleshooting, see Digital Controller Status Mes-
sages.
NOTE: Contact a GMP ASD to change controller mode between AUTO or MANUAL, if desired.

Monitoring, Diagnostic, and Protective Features

Mechanical and electrical systems are connected to vari­ous sensors that monitor unit status. The controller will automatically stop the unit and display fault information if conditions occur outside of predetermined manufacturing parameters. The controller can also display a variety of critical alerts, diagnostics, and recommendations. The controller provides a variety of real-time current operating condition data. See the engine harness wiring diagrams for more information.
Figure 2-5. Controller in AUTO Mode
Button Position MANUAL Mode AUTO Mode
A Increase heat
B Increase fan
Increase temp setting
Decrease temp setting
C Overview/Analog gauge screen
D Main menu
E Heater on/off
F Next screen
G Popup “Softkeys”
10 Owner’s Manual for Flameless Heat Cart

Section 3: Operation

(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.
(000135)
CAUTION
Engine damage. Verify proper type and quantity of engine oil prior to starting engine. Failure to do so could result in engine damage.
(000154)
WARNING
Risk of burns. Do not open coolant system
until engine has completely cooled. Doing so
could result in serious injury.
Operation

Theory of Operation

The flameless heater generates heat by running pressur­ized fluid through a restrictive orifice, which drops the hydraulic pressure and results in heated fluid. A fan then blows air over the heat exchanger to push heated air out through the heat ducts.

Before Starting Engine

Pre-Start Checklist

Remove all flammable materials and fire hazards
within 5 ft (1.5 m) of the unit.
Keep unit a minimum of 10 ft (3 m) from structures
or barricades.
Verify the unit is not leaking fluids: check inside
and outside the unit for leaking fuel, engine oil, HTF/hydraulic oil, and engine coolant.
Verify the following are clear of debris and obstruc-
tions:
– Engine air intake
– Engine exhaust stack
– Outlets and fan intakes
Verify the air duct hose is securely fastened to out-
let duct assembly.
Check fuel, engine oil, hydraulic fluid, and engine
coolant levels.
Verify unit is properly secure and level with the
parking brake engaged.
Inspect the alternator drive belt for tension and
abnormalities.
Verify battery cable connections are not loose or
corroded.
Inspect ducting for damage or unusual wear.

Engine Oil Level Check

NOTE: Wait at least 10 minutes before proceeding if the
engine was running.
1. Remove oil dipstick from crankcase and wipe it clean with a clean, lint free cloth.
2. Insert oil dipstick fully into oil dipstick tube and then remove slowly.
3. Oil level must be between the FULL and ADD marks on the oil dipstick.
4. Add oil (if necessary) to adjust the level. After add­ing or changing the oil, run the engine for one min­ute before checking the oil level. Wait 10 minutes to allow the engine to cool and oil to fully drain into the oil pan.
Typical causes of inaccurate oil level readings:
Reading the high level of oil dipstick.
Reading oil dipstick before oil fully drains into oil
pan.
Inserting and removing oil dipstick too quickly.
Removing and reading the oil dipstick before fully
seating the oil dipstick into oil dipstick tube.

Hydraulic Oil Check

On the hydraulic fluid reservoir tank is a gauge showing hydraulic oil level. Verify level is between MIN and MAX.

Engine Coolant Check

Owner’s Manual for Flameless Heat Cart 11
1. Remove radiator fill cap.
2. Check coolant level and degree of fouling. Level
should be approximately 0.39 in (10 mm) below the radiator core top.
3. Install radiator cap securely.
Operation
WARNING
Burn hazard. Do not remove ducting until all air pressure has been emptied from hose duct. Failure to do so could result in severe injury.
(000288)
(000108)
WARNING
Hot Surfaces. When operating machine, do not touch hot surfaces. Keep machine away from combustibles during use. Hot surfaces could result in severe burns or fire.
WARNING
Crushing hazard. Verify parking brake is 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)
CAUTION
(000291)
Equipment damage. Do not attempt to start or operate a unit in need of repair or scheduled maintenance. Doing so could result in serious injury, death, or equipment failure or damage.
WARNING
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
(000289)
Equipment damage. Do not use starting aids in the engine air intake system. Such aids can cause immediate engine damage.
CAUTION
(000290)
Equipment damage. Do not cover unit during operation. All ducting ports must remain open even if not being used. Failure to do so will result in equipment damage.
001580
CAUTION
(000230)
Equipment Damage. Do not continuously crank engine for more than ten seconds. Doing so will lead to overdischarge of batteries and starter seizure.

Ducting Guidelines

Place ducting in desired configuration before oper-
ating unit.
Tightly secure ducting ends to the unit and the air
craft.
Avoid sharp bends or 90° turns in the ducting.
Use only the necessary length of ducting required;
do not exceed maximum length.
Verify the ducting is not in a high traffic area, and
will not impede workers or other machinery. Care should be taken to eliminate the need to step or climb over ducting.
DO NOT place ducting over combustible materials.
DO NOT place ducting over surfaces that may
damage it or reduce performance, such as water, sharp rocks or glass, electrical wiring, piping, etc.
DO NOT place or drape anything over ducting,
such as covers, insulation, blankets or cloth, elec­trical wires, etc.

Engine and Heater Startup

1. Complete the Pre-Start Checklist.
2. Close all access doors.
NOTE: All doors on the unit must be closed when oper-
ating.
3. Raise tow bar to engage parking brake.
4. See Figure 3-1. Turn ignition key to ON. The
screen displays “Engine Preheat”.
Figure 3-1. Engine Preheat
5. See Figure 3-2. Wait approximately five seconds for fuel pump to build pressure. Turn ignition key to START when the screen displays “Start Engine”.
12 Owner’s Manual for Flameless Heat Cart
Figure 3-2. Start Engine
001584
001585
001586
A
B
6. Attach air ducting to aircraft, avoiding sharp bends and twists in duct.
Operation
9. See Figure 3-5. When the heater is warm, heat begins blowing from ducts, the amber strobe light on top of the unit activates, and the screen displays “Heater On — Press OFF to stop the heater”.
NOTE: A twisted or bent air duct will cause loss of air pressure and temperature.
7. See Figure 3-3. The screen displays “Engine Warming — Please Wait”.
Figure 3-3. Engine Warming
8. See Figure 3-4. Press ON to start the heat sequence. Engine warming is complete and the heater automatically begins warming when coolant temperature reaches 140 °F (60 °C). The screen displays “Heater is warming up—Please wait”.
Figure 3-5. Heater On

Adjusting Heater Output

Use the up and down arrows to adjust temperature selec­tion to desired outlet temperature. The options are 100 °F (38 °C), 120 °F (49 °C), 140 °F (60 °C), and 160 °F (71 °C). Monitor regularly and adjust as needed.

AUTO Mode

In AUTO mode, output temperature is manually set, as follows:
To increase output temperature, press (+) (Figure
3-6, item A).
To decrease output temperature, press (-) (Figure
3-6, item B).
Figure 3-6. AUTO Mode

MANUAL Mode

In MANUAL mode, heater output can be set to minimum fan or maximum fan, as follows:
For minimum fan, press MIN FAN (Figure 3-7, item
Figure 3-4. Heater Warming
Owner’s Manual for Flameless Heat Cart 13
A). Minimum fan produces the highest temperature at the lowest air flow.
Operation
A
B
C
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.
001582
A
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.
For maximum fan, press MAX FAN (Figure 3-7,
item B). Maximum fan produces a lower tempera­ture at a higher air flow.
Figure 3-7. MANUAL Mode

Heater and Engine Shutdown

001583
Figure 3-9. Cooling Complete
2. Turn ignition key to OFF.
1. Press OFF. Heater stops; blower continues running
and a countdown displays. The screen displays “Heater is cooling down — Please wait” (Figure 3-
8).
Figure 3-8. Heater Cooling
NOTE: During cool down, the ON button (A) is disabled.
The blower stops when the countdown expires. The dis­play indicates when it is okay to shut off the engine (Fig-
ure 3-9).
3. Disconnect air duct from airplane.
IMPORTANT NOTE: Do not detach air duct until all air pressure is emptied from the duct.
4. Retract air duct and place in storage area.
5. Turn main battery disconnect to OFF.

Positive Air Shutdown (PAS)

See Figure 3-10. This unit is equipped with a manually activated positive air shutdown (PAS) on the air intake. If the atmosphere contains combustible propane or natural gas, a positive air shutdown can be activated to prevent these gases from being drawn into the engine and ignit­ing.
The PAS system stops the engine by closing an internal valve and obstructing intake air. See Figure 3-11. The PAS is activated by pulling the red T-handle outwards. The reset knob rotates clockwise to block airflow.
14 Owner’s Manual for Flameless Heat Cart
Figure 3-10. Reset Handle in Ready State
Operation
5. Reset the T-handle.
6. Repeat steps in Engine and Heater Startup to
start unit.
Figure 3-11. Emergency Stop T-Handle

Testing the PAS

Test the PAS at least once a month to ensure optimal valve performance.
Pull the T-handle with the unit completely shut down to manually test the PAS. This action triggers an actuator, closing the butterfly valve inside the valve body. An audible click or series of clicks can be heard when the actuator engages. Confirm that the valve is closed by verifying that the reset knob is rotated completely clockwise. If any resistance is felt, or the valve does not close, contact Generac Mobile Products Technical Support.

Resetting the PAS

The emergency PAS system must be reset after each emergency event according to the steps below:
1. Turn the control power switch to OFF (O).
2. Locate the PAS valve located inside the cabinet of
the unit.
3. See Figure 3-11. Pull T-handle on the PAS valve outwards until there is an audible “click”.
4. See Figure 3-10. Turn rest knob counter-clockwise 90 degrees until there is an audible “click”.
Owner’s Manual for Flameless Heat Cart 15
Operation
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16 Owner’s Manual for Flameless Heat Cart

Section 4: Maintenance

(000139)
WARNING
Risk of burns. Allow engine to cool before draining oil or coolant. Failure to do so could result in death or serious injury.
Potential of cancer. Prolonged or repeated contact with used motor oil has been shown to cause cancer in laboratory animals. Thoroughly wash exposed areas with soap and water.
(000127a)
WARNING
A

Maintenance

Maintenance
Regular maintenance will improve performance and extend engine/equipment life. Generac Mobile Products, LLC. recommends that all maintenance work be per­formed by a Generac Mobile Products Authorized Ser­vice Dealer (GMP ASD). Regular maintenance, replacement, or repair of the emissions control devices and systems may be performed by any repair shop or person of the owner’s choosing. To obtain emissions con­trol warranty service free of charge, the work must be performed by a GMP ASD. See the emissions warranty.

Maintenance Tasks

Daily checks must be performed when unit is operated continuously for extended periods of time. Daily checks and routine monthly checks can be performed by an authorized operator.
NOTE: Normal maintenance, service, and replacement of parts are the responsibility of the owner and are not considered defects in materials or workmanship within the terms of the warranty. It is strongly recommended that equipment be periodically checked by a GMP ASD.

Draining and Refilling the Oil

Proceed as follows to drain the oil:
1. See Figure 4-1. Place a suitable container under unit. A drain hose (A) is attached to the drain port and routed through the bottom of the enclosure to drain the oil.

Daily Walk Around Inspection

Check for conditions that could hinder performance or safety, such as (but not limited to) oil, coolant, and fuel leakage, blocked vents, loose or missing hardware, and improper electrical connections. Check for foreign matter blocking the vents and on top of unit.
Inspect outer cover for significant damage beyond
scuffs and small nicks.
Inspect for wire abrasion.
Inspect the fan belt for cracking, fraying, and
stretching. Verify the belt is properly seated in the pulley grooves.
Check coolant.
Check electrical connectors, battery, and ground
points. Look for loose or missing hardware.
Check all flexible rubber hoses for deterioration.
Check hydraulic hoses for signs of wear.
Verify hoses are not crushed, bent, or twisted.
Verify there are no cracks or corrosion.
Inspect ducting for damage or unusual wear.
Figure 4-1. Oil Drain Hose
2. Remove plug from oil drain/manifold.
3. Open drain valve. Drain oil.
4. See engine manual for oil filter information.
5. Close drain valve.
6. Replace plug in drain port on sub base.
7. Dispose of waste oil in accordance with local,
state, or national codes or regulations.
8. See Figure 4-2. Remove filler cap (B) on either the rocker arm cover or on the side of the engine.
Owner’s Manual for Flameless Heat Cart 17
Maintenance
B
(000149)
DANGER
Risk of poisoning. Do not use mouth to siphon coolant. Doing so will result in death or serious injury.
(000154)
WARNING
Risk of burns. Do not open coolant system until engine has completely cooled. Doing so could result in serious injury.
(000165a)
CAUTION
Risk of overheating. Do not use any chromate base rust inhibitor with propylene glycol base antifreeze, boosters, or additives. Doing so will cause overheating and possible equipment damage.
Figure 4-2. Oil Fill Cap Locations
If coolant level is below the filler neck, coolant must be added. (See Coolant Recommendations.) Proceed as follows to add coolant:
1. Verify engine is stopped and cooled.
2. Remove radiator cap.
3. Fill radiator slowly with coolant until it comes up to
filler neck.
4. Operate engine for approximately five minutes at a low idle speed to purge the air in the coolant circuit.
NOTE: Coolant level will drop.
5. Stop the engine and replenish with coolant once
cooled.
9. Fill oil pan to specified level.
10. Replace filler cap.
NOTE: Do not overtighten filler cap. Overtightening may
damage filler cap.
11. Start and run the engine for five minutes. Verify there are no leaks.
12. Stop the engine and let cool for approximately 10 minutes. Verify the oil level is correct. (See Drain-
ing and Refilling the Oil.) Repeat steps 8–10 until
oil is properly filled.
NOTE: Do not overfill oil pan. Overfilling may result in white exhaust smoke, sudden engine overspeed, or engine damage.

Adding Coolant

Maintenance Schedule

Periodic inspection, service, and maintenance of this unit is critical to ensuring reliable operation. The following is the manufacturer’s recommended maintenance sched­ule. The maintenance items need to be performed more frequently if the unit is used in severe applications (such as very high or very low ambient conditions or extremely dirty or dusty environments). Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to determine the next required maintenance interval.
NOTE: Some checks are based on hours of operation.
Follow all applicable safety alerts in this manual or the engine service manual before performing any mainte­nance checks or service.
This maintenance schedule reflects the minimum tasks needed to verify the unit remains operational. Some of the tasks can be performed by an authorized operator, and others must be performed by a GMP ASD.
NOTE: An authorized operator is one who has been trained by a GMP ASD in proper operation and inspec­tion of this unit.
18 Owner’s Manual for Flameless Heat Cart
Maintenance
Engine Maintenance Schedule
To protect the warranty status of the engine, engine maintenance and repairs should be performed by a GMP ASD. For more information on the checks and maintenance described below, see the engine manual.
Check engine oil, coolant, hydraulic oil, and engine fuel levels.
Check radiator filler cap fitting condition.
Inspect alternator drive belt tension and replace if necessary.
Inspect fan belt tension.
Daily
Inspect preheating condition.
Check engine starting condition.
Check exhaust smoke condition.
Inspect hoses and connections.
Inspect exhaust system for wear and cracking.
Every Six Months
Every 12 Months
At 50 Operation Hours (Break In)
At 250 Operation Hours
At 500 Operation Hours
At 750 Operation Hours
Inspect wheel bearings.
Replace coolant.
Change engine oil and oil filter.
Change engine fuel filters.
Replace fuel filter element.
Clean water sedimenter element.
Clean electromagnetic pump filter.
Change engine oil and oil filter element.
Inspect engine accessory drive belts.
Inspect fuel supply system.
Change engine fuel filters.
Inspect alternator drive belt tension, and replace if necessary.
Inspect injection nozzle (*).
Change fuel filter element.
Clean water sedimenter element.
Clean electromagnetic pump filter.
Replace fuel filter element.
Clean water sedimenter element.
Clean electromagnetic pump filter.
Inspect fan belt for wear. Inspect for hard turning or unusual sounds.
Inspect fan belt pulleys and bearings.
Owner’s Manual for Flameless Heat Cart 19
Maintenance
At 1000 Operation Hours
At 1250 Operation Hours
At 1500 Operation Hours
Change engine oil and oil filter element.
Inspect engine accessory drive belts.
Inspect fuel supply system.
Clean cooling system circuit.
Inspect and clean the starter and alternator (*).
Inspect valve clearance (*).
Inspect injection nozzle (*).
Change fuel filter element.
Clean water sedimenter element.
Clean electromagnetic pump filter.
Replace fuel filter element.
Clean water sedimenter element.
Clean electromagnetic pump filter.
Change engine oil and oil filter element.
Inspect engine accessory drive belts.
Inspect fuel supply system.
Clean positive crankcase ventilation valve.
Inspect injection nozzle (*).
Change fuel filter element.
Clean water sedimenter element.
Clean electromagnetic pump filter.
After 1500 Operation Hours
(*) = When servicing these items, consult the equipment supplier.
NOTE: All service and maintenance or repairs are recommended to be completed by a GMP ASD to maintain the warranty status of a unit. You cannot be denied emissions warranty coverage solely based on failure to complete recommended service maintenance.
All hours-based checks and maintenance should now be performed every 250 hours.
Other Maintenance Checks
Every 500 Hours
Every 1000 Hours
Change air filter.
Change hydraulic oil.
Change hydraulic pump filter.
Change hydraulic breather/separator.
Annually
Carbon monoxide (CO) test at outlet air duct by trained service technician.
Inspect blower/fan hardware for condition and tightness.
20 Owner’s Manual for Flameless Heat Cart
Maintenance
(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.
(000181)
WARNING
Vision Loss. Eye protection is required to avoid spray from spark plug hole when cranking engine. Failure to do so could result in vision loss.
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)
(000167a)
CAUTION
Equipment damage. Do not make battery connections in reverse. Doing so will result in equipment damage.

Battery Inspection

Once every six months, a GMP ASD should inspect the battery system. At this time, the battery condition and state of charge should be checked using a load test battery. The battery should be recharged or replaced as required.
Battery service must be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away.
Observe the following precautions when working on batteries:
Remove watches, rings, or other metal objects.
Use tools with insulated handles.
Wear rubber gloves and boots.
Do not lay tools or metal parts on top of battery.
Disconnect charging source prior to connecting or
disconnecting battery terminals.
NOTE: Wash spilled electrolyte down with an acid neu­tralizing agent. A common practice is to use a solution of 1 lb (454 g) bicarbonate of soda (baking soda) to 1 gal (3.8 L) of water. Add bicarbonate of soda solution until the evidence of reaction (foaming) has ceased. Flush the resulting liquid with water.
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
An authorized operator should inspect the engine battery monthly. At this time, the battery fluid level should be checked using a load tester, and distilled water added if needed. Battery cables and connections should also be inspected for cleanliness and corrosion.
Owner’s Manual for Flameless Heat Cart 21
NOTE: Discharge state electricity before touching bat­tery by first touching a grounded metal surface.

Battery Installation and Replacement

When required, the battery must be replaced with one of equivalent size, voltage, and CCA (cold crank amp capacity). Minimum CCA for this unit is 950. Contact a GMP ASD for correct battery size. A new battery must be filled with the proper electrolyte and be fully charge before installing.
Battery cables are connect to the unit at the factory. Connect cables to battery posts as follows:
NOTE: Turn the battery disconnect to OFF before changing the battery.
1. Connect red battery cable from starter contactor to positive (POS or +) battery post.
2. Connect black battery cable to negative (NEG or -) battery post.
3. See Engine and Heater Startup.
Maintenance
CAUTION
(000291)
Equipment damage. Do not attempt to start or operate a unit in need of repair or scheduled maintenance. Doing so could result in serious injury, death, or equipment failure or damage.
WARNING

Other Maintenance Checks

The following inspections should be performed by an authorized service technician, or a properly trained authorized operator. These maintenance items require a high level of experience and skill to evaluate and correct.
Inspect exhaust pipe sleeve.

Short Term Storage

When the unit will not be in use for three or more months, follow the guidelines below to properly store the unit:
Perform all necessary maintenance or repairs
based on the Maintenance Schedule. If neces- sary maintenance is upcoming, perform the main­tenance action before storing.
Fill the fuel tank to FULL.
Fill coolant to FULL. Do not drain.
Remove all dirt and debris from inside and outside
the enclosure.
Lock the unit to prevent any unauthorized opera-
tion.
Store in a safe location — do not position near or
on top of any combustible materials; observe any local, state, or national codes or regulations. Store in a low moisture, low dust area.
Disconnect the negative cable from the battery.

Return to Service

Follow the guidelines below for engines and units that have not been operated for three to six months:
Conduct a thorough inspection of the unit before
starting the engine.
Verify the maintenance schedule is up to date.
Check all fluids for signs of fouling or degradation.
After starting the engine, let it warm up for more
than 10 minutes at idle.
NOTE: Do not start or operate a unit in need of repair or maintenance. Perform all maintenance tasks and repairs before starting. Contact a GMP ASD if there is any doubt as to the unit’s usability.
22 Owner’s Manual for Flameless Heat Cart

Section 5: Troubleshooting

General Troubleshooting Guide
Problem Cause Solution
Troubleshooting
Engine cranks but will not start
Engine will not crank (electric start)
Engine starts but stops shortly thereafter
Engine running is unstable
No fuel.
Insufficient oil level. Replenish oil to full.
PAS is ON. Turn PAS to OFF. See Resetting the PAS.
Air in fuel system. Purge air from fuel system.
Clogged fuel filter. Remove water and change element.
Gelled fuel.
Injection pump failure.
Electromagnetic type fuel pump failure.
Engine control system failure.
LCD panel shows engine failure.
Clogged strainer.
Pre-heating device failure.
Restricted air flow. Check/replace air filter.
Discharged battery.
Battery terminal is disconnected, loose, or corroded.
Starter ground terminal is disconnected, loose, or corroded.
Excessive engine oil viscosity.
Starter or electrical system failure.
Engine seized.
Low idle.
Clogged fuel filter. Remove water and change element.
Clogged pre-fuel filter.
Clogged air cleaner.
Engine control system failure.
Injection pump failure.
Clogged strainer.
Electromagnetic type fuel pump failure.
Fuel system failure.
Water or air in fuel system. Purge air or remove water.
Engine control system failure. Contact a GMP ASD.
Verify there is no fuel leakage and replenish.
Warm fuel pipes with hot water or wait until ambient temperature rises.
Contact a GMP ASD.
Replace battery. See Battery Installation
and Replacement.
Replace corroded part(s) and tighten securely.
Change with oil of correct viscosity. See
Draining and Refilling the Oil.
Contact a GMP ASD.
Adjust by idling control equipment on the unit. If adjustment is not possible, contact a GMP ASD.
Clean or change element.
Contact a GMP ASD.
Owner’s Manual for Flameless Heat Cart 23
Troubleshooting
Problem Cause Solution
Exhaust smoke is white
Exhaust smoke is black
Engine overheats
Oil pressure does not rise
Engine has no power
Insufficient warm-up time. Conduct warm-up operation.
Excessive engine oil.
Engine control system failure.
Injection pump failure.
Fuel system failure.
Excessive idling (more than two hours).
Excessive speed.
Clogged air cleaner. Clean or change element.
Injection pump failure.
Clogged intercooler.
Fuel system failure.
Clogged exhaust system.
No coolant. Add coolant. See Adding Coolant.
Front of radiator is clogged with dust. Clean with soft brush.
Subtank cap is not tightened. Tighten or replace sub tank cap.
Fouled coolant.
Oil in coolant. Contact a GMP ASD.
Thermostat failure. Change thermostat.
Incorrect engine oil viscosity.
Insufficient engine oil.
Engine failure.
Meter, lamp, or switch failure.
Clogged air cleaner.
Clogged pre-fuel filter.
Clogged fuel filter. Remove water and change element.
Clogged strainer.
Engine control system failure.
Engine failure.
Clogged exhaust system.
Fuel system failure.
Incorrect fuel type.
Electromagnetic type fuel pump failure.
Correct oil level. See Draining and Refill-
ing the Oil.
Contact a GMP ASD.
Verify engine rpm.
Check AVR adjustment.
Contact a GMP ASD.
Clean inside of radiator and change coolant.
Change with oil of correct viscosity. See
Draining and Refilling the Oil.
Replenish engine oil. See Draining and
Refilling the Oil.
Contact a GMP ASD.
Clean element.
Contact a GMP ASD.
24 Owner’s Manual for Flameless Heat Cart
Problem Cause Solution
Overheat/shutdown condition (Check controller for engine fault shutdown code)
No/low heat condition
Troubleshooting
Access doors are open. Close all access doors.
Air outlets are closed.
Front radiator or rear oil cooler are full of debris.
Engine rpm is set too high for ambient temperature.
Faulty temperature sensor. Check air outlet sensor operation.
Blower fan operating incorrectly.
Incorrect heater setting (target tempera­ture too low).
Access doors are open. Close all access doors.
Open the air outlets and verify there are no obstructions or tight bends in the ducting.
Clean the unit.
Lower the engine rpm.
Remove ducting; check blower fan opera­tion.
Adjust heater output. See Adjusting
Heater Output.
Check level on tank sight glass, adjust
as needed.
Insufficient HTF/hydraulic oil level.
Inspect HTF hoses for leaks or loose
fittings.
Check fluid for foaming.
Clogged HTF/hydraulic oil filters.
Excessive ducting for ambient conditions.
HTF pump drive sheared. Contact a GMP ASD.
Controller sensor fault. Check sensor related to fault.
Check restriction gauges/replace HTF filters.
Move unit closer to heat recipient if possible.
Owner’s Manual for Flameless Heat Cart 25
Troubleshooting
Digital Controller Status Messages
Message Cause
Engine Warming — Please Wait Engine coolant temperature < 140 °F (38 °C).
Engine Preheat Wait approximately 10 seconds after heater powers up.
Engine rpm < 500 Engine is not ready — Check rpm, Fuel Level or Wait to Start
Low Fuel Warning
Fuel level < 10%
Wait to Start signal
Fuel level < 20%
Fuel level notification appears on screen
Low Fuel Level beacon turns on
Fuel level 16%
Fuel level notification appears on screen
Heat/fan load reduced to 50%
Fuel level 12%
Fuel level notification appears on screen
Open heat circuit and close scroll fan circuit
Drop engine to idle
Fuel level 8%
Fuel level notification appears on screen
Engine shuts down
Check heater settings or connections, then press Reset on the Machine Overview
Heater is cooling down — Please wait
Engine is going to shutdown Fuel level 8%
Engine fault shutdown
Heater shutdown due to temperature; pressure or level out of range
IFM controller detected a short or break in a sender.
IFM controller detects heater is in cool down. ON button
disabled.
Low engine oil pressure
High engine coolant temperature
Engine overspeed
High hydraulic temperature
Low hydraulic pressure
Low hydraulic level
26 Owner’s Manual for Flameless Heat Cart

Section 6: Installation Diagrams

Engine Harness (1 of 3)
Installation Diagrams
Owner’s Manual for Flameless Heat Cart 27
Installation Diagrams
Engine Harness (2 of 3)
28 Owner’s Manual for Flameless Heat Cart
Engine Harness (3 of 3)
Installation Diagrams
Owner’s Manual for Flameless Heat Cart 29
Installation Diagrams
M1
H1
H1
H1
H1
H1
H1
M1
P1
H1
V1
V1
Large Hydraulic
Exchanger
Small Hydraulic
Exchanger
Hydraulic Oil Tank
Fan
Pressure
Regulating
3-Way Valve
Start-up Bypass
3-Way Valve
Filters
Hydraulic System Schematic
30 Owner’s Manual for Flameless Heat Cart
Hydraulic Heat System
ENGINE RADIATOR
C60 HYD EXCHANGER
LARGE EXHAUST EXCHANGER
Installation Diagrams
Owner’s Manual for Flameless Heat Cart 31
Installation Diagrams
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32 Owner’s Manual for Flameless Heat Cart
Installation Diagrams
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Owner’s Manual for Flameless Heat Cart 33
Installation Diagrams
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34 Owner’s Manual for Flameless Heat Cart
Part No. 10000012492 Rev. B 05/16/2018 ©2018 Generac Mobile Products, LLC All rights reserved. Specifications are subject to change without notice. No reproduction allowed in any form without prior written consent from Generac Mobile Products, LLC.
Generac Mobile Products, LLC
215 Power Drive, Berlin, WI 54923
GeneracMobileProducts.com 800-926-9768 920-361-4442
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