Wacker Neuson E3000, E 3000G, E 3000 LB-G, E 3000 LB Operator's Manual

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Operator’s Manual

5000188154

Hydronic Surface Heater

E3000

Type E3000

Document 5000188154

Date 1115

Versio n 05

Language EN

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

This publication may be photocopied by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Production Americas LLC.

Any type of reproduction or distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights. Violators will be prosecuted.

Trademarks

Manufacturer

Original instructions

All trademarks referenced in this manual are the property of their respective owners.

Wacker Neuson Production Americas LLC

N92W15000 Anthony Avenue

Menomonee Falls, WI 53051 U.S.A.

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

www.wackerneuson.com

This Operator’s Manual presents the original instructions. The original language of this Operator’s Manual is American English.

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 HA VE QUESTIONS ABOUT APPLICATIONS.

Other standards govern the use of fuel gases and heat producing products in specific applications. Your local authority can advise you about these.

THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE REGULATIONS OF THE AUTHORITIES HAVING JURISDICTION.

WARNING

Risk of personal injury or machine damage from improper use. f Before using the machine, read and understand all instructions and follow them

carefully.

f The manufacturer is not responsible for damages to goods or persons due to

improper use of this machine.

WARNING

Failure to comply with the precautions and instructions provided with this machine can result in death, serious injury, and property loss or damage from fire, explosion, burns, asphyxiation, carbon monoxide poisoning, and/or electric shock. f Before using the machine, read and understand all precautions and instructions

that have been provided. Follow them carefully.

f Only persons who can understand and follow the precautions and instructions

should use or service this machine.

f Contact the manufacturer if you need assistance with operating the machine or

need replacement manuals or labels.

WARNING

Work site fire, burn, inhalation, and explosion hazards. f Keep solid combustibles, such as building materials, paper, or cardboard at a

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

f Never use this machine in spaces which do or may contain volatile or airborne

combustibles, or products such as gasoline, solvents, paint thinner, dust particles, or unknown chemicals.

WARNING

Not for use in homes or recreational vehicles. Installing this machine in a home or RV may result in fire, explosion, property damage, personal injury, or death.

f Operate the machine only for applications specified in Machine Description and

Intended Use.

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Foreword

SAVE THESE INSTRUCTIONS—This manual contains important instructions for the machine models below. These instructions have been written expressly by Wacker Neuson Production Ame ricas LLC and must be followed during installation, operation, and maintenance of the machines.

Machine Item Number Revision

E 3000 0620158 225 and higher E 3000G 0620219 225 and higher E 3000 LB 0620678 225 and higher E 3000 LB-G 0620679 225 and higher E 3000 LB-G 52000004952 100 and higher

Machine documentation

Expectations for information in this manual

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

Americas LLC will be referred to as Wacker Neuson.

 Keep a copy of the Operator’s Manual with the machine at all times.  Use the separate Parts Book supplied with the machine to order replacement

parts.

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

repairing the machine.

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

order a replacement or visit www.wackerneuson.com.

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

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

 This manual provides information and procedures to safely operate and

maintain the above Wacker Neuson model(s). For your own safety and to reduce the risk of injury , carefully read, underst and, and observe all instructions described in this manual.

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

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

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

up until the time of publication. Wacker Neuson reserves the right to change any portion of this information without notice.

CALIFORNIA Proposition 65 Warning

Laws pertaining to spark arresters

Engine exhaust, some of its constituents, and certain vehicle components, contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

NOTICE: State Health Safety Codes and Public Resources Codes specify that in certain locations spark arresters be used on internal combustion engines that use hydrocarbon fuels. A spark arrester is a device designed to prevent accidental discharge of sparks or flames from the engine exhaust. Spark arresters are qualified and rated by the United St ates Forest Service fo r this purpose. In order to

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Foreword

comply with local laws regarding spark arresters, consult the engine distributor or the local Health and Safety Administrator.

Manufacturer’s approval

This manual contains references to approved parts, attachments, and modifications. The following definitions apply:

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

Wacker Neuson.

 Approved modifications are those performed by an authorized Wacker

Neuson service center according to written instructions published by Wacker Neuson.

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

meet the approved criteria.

Unapproved parts, attachments, or modifications may have the following consequences:

 Serious injury hazards to the operator and persons in the work area  Permanent damage to the machine which will not be covered under warranty

Contact your Wacker Neuson dealer immediately if you have questions about approved or unapproved parts, attachments, or modifications.

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Foreword

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E 3000

Table of Contents

Foreword 3

1 Safety Information 11

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

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

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

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

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

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

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

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

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

2 Labels 22

2.1 Label Locations .................................................................................. 22

2.2 Label Meanings .................................................................................. 24

3 Lifting and Transporting 30

3.1 Lifting the Machine ............................................................................. 30

3.2 Preparing the Machine for Transport on a Truck or Trailer ................ 31

3.3 Transporting the Machine on a Truck or Trailer ................................. 32

3.4 Before Towing Checklist ..................................................................... 34

3.5 Towing the Machine ........................................................................... 35

3.6 Testing the Breakaway System (Electric Brakes) .............................. 36

3.7 Hazardous Materials Placards ........................................................... 38

4 Operation 40

4.1 External Components ......................................................................... 40

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

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

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

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

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

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

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

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

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

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

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Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

4.29 Operating States of the Beckett Burner Controller ..............................73

E 3000

5 Accessories 78

5.1 Available Accessories .........................................................................78

5.2 Expanding the Surface Heating Capacity ............................................79

5.3 Expanded Operation Using One HHS 3002 and One DPP .................80

5.4 Expanded Operation Using Two HHS 3002 and Two DPP .................82

5.5 Mounting and Connecting the Auxiliary Pump Panel ..........................85

5.6 Using Heat Exchangers to Heat Air .....................................................87

5.7 Connecting Six HX 50 Heat Exchangers .............................................88

5.8 Connecting Five HX 50 Heat Exchangers ...........................................90

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

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

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

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

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

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

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

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

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

6 Burner Setup—Oil 109

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

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E 3000

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

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

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

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

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

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

Table of Contents

7 Burner Setup—Gas 120

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

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

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

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

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

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

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

7.8 Adjusting the Combustion Head ....................................................... 129

7.9 Checking the Supply Gas Pressure ................................................. 130

7.10 Checking and Adjusting the Burner Gas Pressure ........................... 132

8 Maintenance 134

8.1 Periodic Maintenance Schedule ....................................................... 134

8.2 Inspecting the HTF System and the Fuel System ............................ 135

8.3 Repairing a Hose .............................................................................. 136

8.4 Inspecting the Electrical Components .............................................. 138

8.5 Filling the HTF Reservoir .................................................................. 140

8.6 Cleaning the HTF Strainer ................................................................ 142

8.7 Replacing the Fuel Filter .................................................................. 144

8.8 Lubricating the Hose Reel System ................................................... 145

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

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

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

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

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

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

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

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

9 Genset Maintenance 155

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

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Table of Contents

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

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

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

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

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

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

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

E 3000

10 Troubleshooting 169

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

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

10.3 Troubleshooting the Gas Burner .......................................................172

11 Technical Data 173

11.1 Machine .............................................................................................173

11.2 Trailer ................................................................................................174

11.3 Dimensions ........................................................................................174

MSDS: Dowfrost HD 50 175

Fuji Temperature Controller 183

Tire Safety Information 187

12 Schematics 200

12.1 Composite Schematic—Machine with Oil Burner ..............................200

12.2 Composite Schematic—Machine with Gas Burner ...........................201

12.3 Electrical Schematic Components .....................................................202

12.4 Circulation System Circuit .................................................................205

12.5 Rewind System Circuit ......................................................................206

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

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

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

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

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

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

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E 3000 Safety Information

1 Safety Information

1.1 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. It is used to alert you to potential personal hazards. f Obey all safety messages that follow this symbol.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

f To avoid death or serious injury from this type of hazard, obey all safety

messages that follow this signal word.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

f To avoid possible death o r serious injury from this type of hazard, obey all safety

messages that follow this signal word.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

f To avoid possible minor or moderate injury from this type of hazard, obey all

safety messages that follow this signal word.

NOTICE: Used without the safety alert symbol, NOTICE indicates a situation which, if not avoided, could result in property damage.

Note: A Note contains additional information important to a procedure.

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Safety Information E 3000

1.2 Machine Description and Intended Use

This machine is a hydronic surface heater. The Wacker Neuson Hydronic Surface Heaters consist of trailer-mounted enclosures that house an optional diesel generator , a hydronic heater, electric motors, fixed pump(s) and plumbing , a diesel (or gas) burner, a fuel tank, and a hose handling system.

The hydronic heating system utilizes a burner that indirectly warms the Heat Transfer Fluid (HTF). The warmed HTF is continuously circulated through a vented, closed loop hose system. A positive displacement pump pushes the warmed HTF through the hose system, thereby radiating and transferring the heat to the required application area.

An insulated blanket may be laid over the hoses to increase efficiency. The low HTF level protection device shuts down the machine if the HTF level drops below minimum operational capacity.

This machine is intended to be used as a surface heater in order to thaw frozen ground, to cure concrete, or to prevent frost and freezing. 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. Using the machine for any other purpose could permanently damage the machine or seriously injure the operator or other persons in the area. Machine damage caused by misuse is not covered under warranty.

The following are some examples of misuse:

 Using the machine to heat anything other than what is stated above  Using the machine to pump anything other than the factory recommended Heat

Transfer Fluid

 Using the generator (if equipped) to power anything other than the machine

itself or Wacker Neuson accessory machines, as instructed in the Operator's Manual

 Using the machine as a ladder, support, or work surface  Using the machine to carry or transport passengers or equipment  Using the machine to tow other machines  Operating the generator (if equipped) in a manner that is inconsistent with all

federal, state, and local codes and regulations

 Operating the machine outside of factory specifications  Operating the machine in a manner inconsistent with all warnings found on the

machine and in the Operator’s Manual

This machine has been designed and built in accordance with the latest global safety standards. It has been carefully engineered to eliminate hazards as far as practicable and to increase operator safety through protective guards and labeling. However, some risks may rema in even after protective measures have been t aken. They are called residual risks. On this machine, they may include exposure to:

 Heat, noise, and exhaust from the engine or hydronic heater  Burns from the HTF or radiant heat from the hoses

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E 3000 Safety Information

 Fire hazards from improper refueling techniques  Fuel and its fumes  Personal injury from improper lifting of the trailer tongue  Tripping hazards from the hoses

To protect yourself and others, make sure you thoroughly read and understand the safety information presented in this manual before operating the machine.

1.3 Safety Guidelines for Operating the Machine

Operator training

Operator qualifications

Before operating the machine:

 Read and understand the operating instructions contained in all manuals

delivered with 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.

Only trained personnel are permitted to start, operate, and shut down the machine. They also must meet the following qualifications:

 have received instruction on how to properly use the machine  are familiar with required safety devices

The machine must not be accessed or operated by:

 children  people impaired by alcohol or drugs

Machine condition

Only operate the machine when:

 All safety devices and guards are in place and in working order.  All controls operate correctly.  The machine is set up correctly according to the instructions in the Operator’s

Manual.

 The machine is clean.  The machine’s labels are legible.

When operating the machine:

 Do not modify or defeat the safety devices.  Do not use worn electrical cords.  Do not use faulty fuel supplies.

Safe operating practices

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When operating this machine:

 Remain aware of the machine’s moving parts. Keep hands, feet, and loose

clothing away from the machine’s moving parts.

Safety Information E 3000

When operating this machine:

 Do not operate a machine in need of repair.

Personal Protective Equipment (PPE)

Work space

Wear the following Personal Protective Equipment (PPE) while operating this machine:

 Close-fitting work clothes that do not hinder movement  Safety glasses with side shields  Hearing protection  Safety-toed footwear

When operating the machine:

 Position the machine on a firm, noncombustible, level surface, and chock the

wheels.

 Position the machine on the job site so that neither it nor the operator are

standing in water.

 Keep the area immediately surrounding and underneath the machine clean,

neat, and free of debris and combustible materials.

 Keep the area above the machine clear of debris that could fall on the machine.  Store the machine properly when it is not being used.  Keep unauthorized personnel, children, and pets away from the machine.

When operating the machine:

 Never operate the machine in areas that contain flammable objects, fuels, or

products that produce flammable vapors.

1.4 Safety Guidelines for Lifting the Machine

When lifting the machine:

 Make sure slings, chains, hooks, ramps, jacks, forklifts, cranes, hoists, and any

other type of lifting device used is attached securely and has enough weightbearing capacity to lift or hold the machine safely. See section Technical Data for machine weight.

 Remain aware of the location of other people when lifting the machine.  Only use the lifting points and tie-downs described in the Operator’s Manual.  Make sure the transporting vehicle has sufficient load capacity a nd platform size

to safely transport the machine.

To reduce the possibility of injury:

 Do not stand under the machine while it is being lifted or moved.  Do not get onto the machine while it is being lifted or moved.

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E 3000 Safety Information

1.5 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. Exposure to carbon monoxide can kill you in minutes.

f Never run the machine indoors or in an enclosed area unless the machine is

vented properly.

When refueling the machine:

 Do not fill or drain the fuel tank near an open flame or while the machine is

running.

 Do not smoke when refueling the machine.  Do not use gasoline, crankcase oil, or any oil containing gasoline.

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Safety Information E 3000

1.6 Safety Guidelines for Operating Gensets

DANGER

f Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot smell the exhaust, you could be breathing CO.

WARNING

Electrocution hazard. Generators present special hazards during operation and servicing. These include the risk of electrocution or severe electrical shock. Failure to follow the safety information below can result in severe injury or death.

f Read and follow the safety instructions in this Operator’s Manual. f Contact the genset manufacturer for additional information regarding the

genset.

WARNING

Internal combustion engines present special hazards during operation and fueling. Failure to follow the warnings and safety instructions could result in severe injury or death.

f Read and follow the safety instructions in this Operator’s Manual. f Contact the genset manufacturer for additional information regarding the

genset.

General precautions

WARNING

Most used oil contains small amou nts of materials tha t can cause cancer and oth er health problems if inhaled, ingested, or left in contact with skin for prolonged periods of time.

f Take steps to avoid inhaling or ingesting used engine oil. f Wash skin thoroughly after exposure to used engine oil.

This machine is built with user safety in mind; however, like any electrical device it can present serious hazards if improperly operated and serviced. Follow instructions carefully. Should questions arise during operation or service of this equipment, contact your Wacker Neuson dealer.

 Keep a multi-class, type ABC or equivalent fire extinguisher at hand when using

the genset. Refer to NFPA No. 10 for further information regarding fire extinguishers.

 Do not use evaporative starting fluids. They are highly explosive.  Do not store items such as excess oil, oil rags, tools within the genset

compartment. Items stored within the genset compartment are a fire hazard and can restrict cooling air.

 Wash thoroughly after handling used engine oil.

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E 3000 Safety Information

Before operating the genset

Running the genset

Refueling safety

 Know how to start, operate, and stop the genset before starting it.  Obtain the proper training for operating the genset. Do not allow untrained

personnel to operate or service the genset.

 Check the fuel lines and the fuel tank for leaks and cracks before starting the

engine.

 Clean the genset of any spilled fuel.

 Do not start the engine if fuel has spilled or a fuel odor is present.  Keep the area around the exhaust pipe free of flammable materials.  Do not smoke while operating the genset.  Keep sparks, flames, electrical arcs, and other sources of ignition far away from

the genset.

 Do not touch the engine or muffler while the engine is running or immediately

after it has been turned off.

 Do not operate the genset with the maintenance covers off.  Do not overload the genset. The total amperage of the tools and equipment

attached to the genset must not exceed the load rating of the genset.

 Do not operate the genset with wet hands.  Do not remove the radiator cap when the genset is running or is hot.

When adding fuel to the fuel tank:

 Do not smoke.  Do not refuel a hot or running engine.

Maintenance safety

When adding fuel to the fuel tank:

 Keep sparks, flames, electrical arcs, and other sources of ignition far away from

the genset.

 Refill the fuel tank only in a well-ventilated area.  Reinstall the fuel tank cap after refueling.

 Only a trained technician should attempt to repair the genset.  Test procedures which require that the generator be running must be performed

using extreme caution.

 Make sure clothing and shoes are dry , st and on a dry wooden plat form or rubber

insulating mat, and use tools with insulated handles when servicing the genset.

 Engine antifreeze is toxic to humans and animals. Clean up spills and dispose

of used engine antifreeze in accordance with local environmental regulations.

 Make sure all fasteners are secure and torqued properly.

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Safety Information E 3000

1.7 Service Safety

Service training

Precautions

Before servicing or maintaining the machine:

 Read and understand the instructions contained in all manuals delivered with

the machine.

 Familiarize yourself with the location and proper use of all controls and safety

devices.

 Only trained personnel shall troubleshoot or repair problems occurring with the

machine.

 Contact Wacker Neuson for additional training if necessary.

When servicing or maintaining this machine:

 Do not allow improperly trained people to service or maintain the machine.

Personnel servicing or maintaining the machine must be familiar with the associated potential risks and hazards.

Follow the precautions below when servicing or maintaining the machine.

 Read and understand the service procedures before performing any service to

the machine.

 All adjustments and repairs must be completed before operating the machine.

Do not operate the machine with a known problem or deficiency.

 All repairs and adjustments shall be completed by a qualified technician.  Turn off the machine before performing maintenance or making repairs.  Remain aware of the machine’s moving parts. Keep hands, feet, and loose

clothing away from the machine’s moving parts.

 Reinstall the safety devices and guards after repair and maintenance

procedures are complete.

Machine modifications

Replacing parts and labels

Cleaning

When servicing or maintaining the machine:

 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.

 Replace worn or damaged components.  Replace all missing and hard-to-read labels.  When replacing electrical components, use components that are identical in

rating and performance to the original components.

 When replacement parts are required for this machine, use only Wacker

Neuson replacement parts or those p arts equivalent to the original in all types of specifications, such as physical dimensions, type, strength, and material.

When cleaning and servicing the machine:

 Keep the machine clean and free of debris such as leaves, paper, cartons, etc.  Keep the labels legible.

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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 Protective Equipment (PPE)

Maintenance guidelines

Wear the following Personal Protective Equipment (PPE) while servicing or maintaining this machine:

 Close-fitting work clothes that do not hinder movement  Safety glasses with side shields  Hearing protection  Safety-toed footwear

In addition, before servicing or maintaining the machine:

 Tie back long hair.  Remove all jewelry (including rings).

When maintaining the machine:

 Keep the fuel lines in good condition and properly connected.  Allow the burner to cool before maintaining the machine.  Allow the Heat Transfer Fluid (HTF) to cool before maintaining the machine.  Keep all electrical cords away from heat, oil, vibrating surfaces, and sharp

edges.

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Safety Information E 3000

1.8 Safety Guidelines for Towing the Machine

WARNING

Risk of severe injury or death. Improper trailer condition and towing technique can lead to an accident.

f 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.

 Do not tow the machine if any of the trailer’s lug nuts are missing.  Do not tow the machine if the trailer’s tires have less than 1.5 mm (1/16 inch) of

tread.

 Do not tow the machine unless the trailer’s brakes are functioning properly.  Do not exceed the trailer manufacturer’s speed limitations.

When towing the machine:

 Only tow the machine when the trailer’s lug nuts are properly torqued.  Only tow the machine when the trailer’s tires are properly inflated.  Only tow the machine when all trailer lights are functioning correctly.  Only tow the machine when the trailer’s safety chains are connected to the

towing vehicle in a crisscross pattern.

 Maintain extra distance between the towing vehicle and other vehicles.  Avoid soft shoulders, curbs, and sudden lane changes  Abide by all licensing requirements for your area.

If you have not driven a towing vehicle with trailer before, practice turning, stopping, and backing up the towing vehicle with trailer in an area away from traffic. Only drive the towing vehicle with trailer when you are confident in your ability to do so.

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E 3000 Safety Information

1.9 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. However, NHTSA cannot become involved in individual problems between you, your dealer, or Wacker Neuson.

To contact NHTSA, you may either contact the Vehicle Safety Hotline toll-free at 1-888-327-4236 (TTY: 1-800-424-9153), go to http://www.safercar.gov; or write to:

Administrator NHTSA 1200 New Jersey Avenue S.E. Washington, DC 20590

You can also obtain other information about your motor vehicle safety from http://www.safercar.gov

wc_si000579gb.fm

Labels E 3000

2 Labels

2.1 Label Locations



 

603

  

601

999



618

  

626

  

602

  

608

 

998

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E 3000 Labels

  

 

616

609

  

625



608

995

 

604

  

613



600

612

  

617

607

 

 

602 611

  

616

  

 

609

 

612

618

  

613

619

  

626

 

602

wc_si000643gb.fm

  

625

  

613

wc_gr008849

Labels E 3000

2.2 Label Meanings

Ref. Label Definition

600

For machines powered by the generator:

Use a 50-50 blend of #2 diesel and #1 diesel plus additives, or a 50-50 blend of #2 diesel and K1 kerosene plus additives when temperatures are below 5°F (-15°C).

Use a 70-30 blend of #2 diesel and #1 diesel plus additives or a 70-30 blend of #2 diesel and K1 kerosene plus additives when temperatures are in the range 5 to 25°F (-15 to -4°C).

Use a winter-blend diesel when temperatures are above 25°F (-4°C).

For machines powered by the power utility:

Use 100% #1 diesel plus additives or 100% K1 kerosene plus additives when temperatures are below are below 5°F (-15°C).

wc_gr008377

601 Turn the handle clockwise to engage the

hose reel brake. Turn the handle counterclockwise to release the hose reel brake.

602 WARNING!

WARNING

WARNUNG

ADVERTENCIA

AVERTISSEMENT

173199

Hot surface hazard. Wear safety gloves. Wear eye protection.

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E 3000 Labels

Ref. Label Definition

603 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 Transfer Fluid reservoir.

604 WARNING!

WARNING

WARNUNG

ADVERTENCIA

AVERTISSEMENT

Do not engage trailer jack while transporting the machine. Refer to the Operator’s Manual for further instructions.

607 Do not reset.

wc_si000643gb.fm

173200

173201

Refer to Operator’s Manual.

Labels E 3000

Ref. Label Definition

608 Tie-down location marker.

609 NOTICE!

CAUTION

Lift point. Attach lifting device in this location.

VORSICHT

PRECAUCION

PRECAUTION

611 WARNING!

WARNING

Hand entanglement hazard. Moving parts can crush and cut. Do not operate with guard removed.

173224

WARNUNG

ADVERTENCIA

AVERTISSEMENT

612 CAUTION!

Hot surface hazard!

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E 3000 Labels

Ref. Label Definition

613 Not a step.

616 Weight/mass label: This label indicates the

total weight of the machine, including the

8582

trailer and a full fuel tank.

3900

617 CAUTION

This machine uses diesel fuel.

618

DANGER Asphyxiation hazard.

Using a Hydronic Surface Heater indoors CAN KILL YOU IN MINUTES. Generator and burner exhaust contains carbon monoxide. This is a poison you cannot see or smell.

Never use inside an enclosed area even if doors and windows are open.

Only use outside away from windows, doors, and vents.

Read manual before use.

wc_si000643gb.fm

Labels E 3000

Ref. Label Definition

619

Machine rating label: This label indicates rating information for the machine.

625 WARNING!

Lugnuts factory torqued to 110 ft.lbs. Verify lugnuts are properly torqued before transporting. Failure to heed above warning could result in wheel loss which can cause injury or death.

— Magnetic placards that display the numeric

hazardous material code for diesel fuel are included with each machine. These placards must be placed on three sides of the machine during transport if the fuel tank contains any amount of fuel or fuel residue.

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E 3000 Labels

Ref. Label Definition

626 CAUTION!

CAUTION VORSICHT ATENCION

ATTENTION

183255

Pressurized contents. Do not open when hot!

995 WARNING!

Never operate in an explosive environment or near flammable vapors, fuels or combustibles. Explosion or fire may occur. Risk of severe injury or death.

Nunca opere en un ambiente explosivo o cerca de los vapores inflamables, gasolina o combustibles. Explosión o un incendio puede ocurrir. Riesgo de lesiones graves o la muerte.

Ne faire jamais fonctionner dans un environnement explosif ou à proximité des vapeurs inflammables, des carburants ou combustibles. Explosion ou un incendie peut se produire. Risque de blessures graves ou la mort.

WARNING

ADVERTENCIA

AVERTISSEMENT

5200002911

Never operate in an explosive environment or near flammable vapors, fuels or combustibles. Explosion or fire may occur. Risk of severe injury or death.

998 (on trailer)

The weight of cargo should never exceed

Tire and loading information label: This label indicates tire and loading information for the trailer.

(on trailer) VIN label. This label displays vehicle identifi-

cation numbers and other related information.

999 A nameplate listing the model number, item

number, revision number, and serial number is attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model number, item nu mber , revision number, and serial number of the unit.

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Lifting and Transporting E 3000

3 Lifting and Transporting

3.1 Lifting the Machine

Requirements

Procedure

 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.

f Never stand under, or get onto, the machine while it is being lifted or moved. f Use only the designated lifting points to lift the machine.

Follow the procedure below to lift the machine.

1. Attach the lifting equipment to one of the lifting eyes (a) on the machine using hooks, shackles, and chains.

2. Lift the machine a small distance.

WARNING

Crushing hazard. An unstable machine may cause the lifting devices to fail. You may be crushed if the lifting devices fail.

f Check for stability before continuing.

3. Check for stability. If necessary, lower the machine, reposition the lifting device, and lift the machine a small distance again.

4. Continue lifting the machine as necessary.

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E 3000 Lifting and Transporting

3.2 Preparing the Machine for Transport on a Truck or Trailer

Requirements

Checklist

 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. f Use only the designated tie-down points to secure the machine to a truck or

trailer.

Before transporting the machine, check the following items:

Machine

 Check that all accessories are securely stored within the machine.  Check that all doors and access panels of the machine are closed.  Check that all electrical supplies are disconnected from the machine.  For machines with external fuel supplies, check that all fuel supplies are

disconnected from the machine.

 For machines with generators, check that the generator is shut down.

Loading and transporting equipment

 Check t hat the transport vehicle or trailer can sup port the weight of the machine.  Check that the transport vehicle or trailer is wide enough to support the

machine.

 Check that the wheels of the transport vehicle or trailer are chocked during the

loading process.

 Check that the transport vehicle or trailer is clean and free of grease, oil, ice,

and other loose material.

 If the machine is mounted to a trailer , check that the jackstand or other transport

block (piece of wood or other similar material) is available to support the trailer tongue during transporting. Do not use the machine’s trailer jack to support the trailer tongue during transporting.

 Check that any ramps used in the loading process:

 Can support the weight of the machine  Are clean and free of grease, oil, ice, and other loose material.  Are securely connected to the transport vehicle or trailer.  Are of sufficient length to keep the loading angle 15° or less.

In addition:

 Check that the loading area is flat and the ground is stable.  Check the overall height of the machine once loaded. Plan your travel route so

there will be adequate clearance for overpasses, road signs, buildings, etc.

 Check local regulations regarding transporting and obey these regulations.

ghi_tx001160gb.fm

Lifting and Transporting E 3000

3.3 Transporting the Machine on a Truck or Trailer

Requirements

Move the machine

 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. f Use only the designated tie-down points to secure the machine.

NOTICE: Do not run chains or straps across painted surfaces. Chains or straps may damage your machine.

1. Move the machine onto the flat bed using properly rated ramps or docks.

NOTICE: The flat bed must be at least 98 inches wide.

Support the tongue

2. Raise the tongue using the trailer jack (a).

3. Install the tongue support (b) using two 5/8 inch bolts.

NOTICE: If the supplied tongue support is missing, use any mechanism capable of supporting the tongue weight.

4. Lower the tongue and retract the trailer jack (a) at least two inches from the surface of the truck bed.

This procedure continues on the next page.

ghi_tx001160gb.fm

E 3000 Lifting and Transporting

Continued from the previous page.

Secure the machine

5. Install properly rated securing mechanisms (d) such as chains or straps.

6. Install chocks (e) under all four wheels.

Result

The machine is ready to be transported.

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Lifting and Transporting E 3000

3.4 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. See Technical Data.

 Check that the hitch of the towing vehicle and coupler of the trailer are

compatible.

 Check the condition of both the coupler and the hitch.  Check that all fasteners on the coupler are secure.  Check that the coupler has fresh grease applied to it.

Wheels

 Check that all lug nuts are in place and are properly torqued.  Check the tread wear of the tires.  Check that the tires are inflated to the proper pressure.

Trailer operation

 Check that the directional and running lights on the trailer function correctly.  Check that the safety chains of the trailer are connected to the towing vehicle

using a crisscross pattern.

 Check that the trailer’s breakaway cable is attached to the towing vehicle.  Check the opera tion of the trailer brakes by braking the towing ve hicle at a slow

speed. Both the vehicle and the trailer must brake smoothly. If the trailer pushes, check the fluid level in the surge brakes or the operation of the electric brakes.

 Test the function of the breakaway system.

ghi_tx001160gb.fm

E 3000 Lifting and Transporting

3.5 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. f 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.

Procedure

Perform the procedure below when towing the machine.

1. Read and follow the towing safety guidelines. See topic Safety Guidelines for Towing the Machine.

2. Complete the shut-down procedures. See topic Stopping and Packing Up the Machine.

3. Adjust the amount of fuel in the machine to approximately 70% cap acity to avoid fuel spillage.

4. Complete the Before Towing Checklist. See topic Before Towing Checklist.

5. Connect the machine to the towing vehicle.

6. Rotate the trailer jack to a horizontal position.

7. Tow the machine as needed.

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Lifting and Transporting E 3000

3.6 Testing the Breakaway System (Electric Brakes)

Requirements

When

Procedure

 Voltmeter  Battery charger or backup battery (charged)

Test the breakaway system:

 Before towing  Monthly if the machine is not in service

Perform the following procedure to test the breakaway system. NOTICE: Disconnect the trailer wiring plug from the tow vehicle before testing.

Failure to do so will result in severe damage to the electronic brake control.

1. Connect the machine/trailer to the tow vehicle.

2. Disconnect the trailer wiring plug (a) from the tow vehicle.

wc_gr008470

3. Pull the breakaway pin (b) out of the brake switch (c) (to activate the brakes) and attempt to tow the machine/trailer at a very slow speed (less than 5 mph (8 km/hr)). When activated, a properly working breakaway system will cause substantial drag on the trailer wheels and may even cause the trailer wheels to lock.

4. Stop the tow vehicle.

WARNING

Personal injury hazard. A faulty breakaway system may lead to an accident and personal injury if the machine/trailer breaks away.

f Do not tow the machine/trailer if the breakaway system is faulty.

This procedure continues on the next page.

wc_gr008471

ghi_tx001160gb.fm

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 so:

a.Remove the cover of the battery box. b.Remove the wires connected to the breakaway battery (d). c.Measure the voltage. If 12–14 VDC is not measured, replace or recharge the

breakaway battery.

1000

200

2 200m

V- COM

VDC

wc_gr008472

6. If 12–14 VDC was measured but the brakes did not function, there is a wiring or mechanical fault with the brakes. Repair any faults before towing.

Result

7. If the brakes function properly: a.Reconnect the wires to the breakaway battery.

b.Reinstall the cover to the battery box. a.Reinstall the breakaway pin (b) into the brake switch. b.Connect the trailer wiring plug to the tow vehicle.

The procedure to test the breakaway system is now complete.

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Lifting and Transporting E 3000

3.7 Hazardous Materials Placards

Hazardous materials placards

The Pipeline and Hazardous Materials Safety Administration (PHMSA) requires that hazardous materials placards be placed on this machine when transporting it unless the fuel tank has been drained and purged of all fuel and residue.

Before transporting the machine:

1. Drain and purge the fuel tank of all fuel and fuel residue OR place placards that display the numeric hazardous material code for diesel fuel on three sides of the machine.

Note: The placards are included with the machine.

2. Consult the Department of Transportation (DOT), or equivalent agency, in the states or countries in which this machine is to be transported, regarding:

 Driver’s licensing requirements for transporting machines that bear hazard-

ous materials placards

 Other restrictions for use of this machine

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E 3000 Lifting and Transporting

Notes

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Operation E 3000

4 Operation

4.1 External Components

Ref. Description Ref. Description

1 Hitch (ball or pintle) 6 Fender 2 Tie-down 7 Onan genset (option) 3 Fuel tank 8 Jack stand 4 Fuel tank cap 9 Tandem axles 5 Performance monitoring light 10 Lifting bail

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E 3000 Operation

4.2 Internal Components

wc_gr008296

Ref. Description Ref. Description

a Hydronic heater

h Fill valve #3 b Burner (oil burning shown) i HTF pumps c Suction valve #2 j Low-level shut-down device d Fuel filter k Thermocouple e Battery l Temper ature/pressure gauges

f Fuel sight gauge m HTF filter

g Fuel sight gauge valve n Motor (HTF pump)

This hydronic heater operates at zero (atmospheric) pressure and is not subject to regulations

applicable to pressurized “boilers”.

wc_tx001951gb.fm

Operation E 3000

4.3 Rear Components

Ref. Description Ref. Description

Control panel

Heat Transfer Fluid (HTF) return

plumbing HTF supply plumbing

Hose reel brake T-handle

Rewind system foot control pedal

HTF expansion tank sightglass

Hose reels and hose

Pump Pack supply connections

Duplex receptacle

Operator’s Manual holder

Thermal switch (snap switch)

—

wc_tx001951gb.fm

E 3000 Operation

4.4 Pumps, Gauges, and Valves

Pumps and Gauges

Valves

Ref. Description

aLeft pump b Return flow indicator c Accessory HTF return thermometer d Main HTF return thermometer e Check valves

f Pump pressure gauge

g Right pump

Valve # Description

1 Pump Pack supply and drain valve 2 Pump suction valve (behind hose

reel) 3 HTF fill valve (behind hose reel) 4 Left hose reel supply valve 5 Cross connect valve 6 Right hose reel supply valve 7 Pump Pack supply valve

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Operation E 3000

4.5 Control Panel

wc_gr008606

wc_tx001951gb.fm

E 3000 Operation

4.6 Control Panel Components

Ref Description Function

a Main breaker 1 Controls power to electrical circuit 1. b Hour meter Meters usage of the machine. c Main breaker 2 Controls power to the pump circuit (20A) d Circuit 2 GFCI Provides protection for the operator. e Temperature control

f Cab light ON-OFF switch Switches electric power ON and OFF to the

g Hose rewind ON-OFF (right and

left) switch

h Burner ON-OFF switch Switches electric power ON and OFF to the

i Pump 2 ON-OFF switch Switches electric power ON and OFF to

j Pump 1 ON-OFF switch Switches electric power ON and OFF to

k HTF fill switch This momentary switch bypasses the low-

l Low level fault indicator Illuminates to indicate a low HTF level condi-

 Allows the user to control the HTF target

application temperature.

 Shows the actual temperature of the HTF.

cab light. Controls power to the hose rewind motor.

This switch has two ON modes—one each in the up and down positions. OFF mode is in the middle position.

burner.

Pump 2.

Pump 1.

level shut-down device and provides power to the pumps. It is used when filling the HTF reservoir after a low level fault.

tion.

m Burner fault indicator Illuminates to indicate a burner fault condi-

n Circuit 1 GFCI Provides protection for the operator. o Thermal switch (snap switch)

p HTF low-level reset switch (mod-

ule is located inside the auxiliary control panel)

wc_tx001951gb.fm

tion.

Disconnects power to the burner circuit in the event of an over-temperature condition. This switch opens at 88°C (190°F). This switch must be manually

Pressing this switch resets the low-level shut-down device.

reset.

Operation E 3000

4.7 Genset Control Panel

Ref 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_gr008140

wc_tx001951gb.fm

E 3000 Operation

4.8 Preparing the Machine for First Use

Preparing for first use

To prepare your 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.

3. Take inventory of all items included with the machine and verify that all loose components and fasteners are accounted for.

4. Attach component parts not already attached.

5. Add fluids as needed and applicable, including fuel, engine oil, and battery acid.

6. Move the machine to its operating location.

4.9 Breaking in the Genset

Background

Procedure

New gensets require a break-in period for the engine. If you are the first owner of this machine, or the genset’s engine has just been rebuilt, break in the engine as stated below.

1. Check that the engine oil level is correct. Check that the engine oil viscosity is appropriate for the temperature conditions. Change the oil if it is not appropriate for the temperature conditions.

2. Operate the genset at approximately 1/2 rated power for the first two hours.

3. Operate the genset at approximately 3/4 rated power for two more hours.

4. Check the engine oil level every four hours (or twice daily) during the first 24 hours of operation.

5. Change the engine oil and filter after the first 50 hours of operation.

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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.

2. Check fuel level. 4.13 / 4.15

3. Position the machine. At the job site. 4.14

4. Perform pre-starting checks. 4.15

5. Connect power. 4.16

6. Start the generator (if equipped) 4.17

7. Power up the machine. 4.18

8. Run the machine. — a. Preheat the HTF (if necessary). 4.19 b. Initiate HTF flow. 4.20 c. Unwind and position the hoses. 4.22 / 4.23 d. Monitor the operating parameters. 4.24

Or, when at the job site before daily operation.

4.11 / 4.15

e. Rewind the hoses. 4.25

9. Shut down and pack up the machine. 4.26

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E 3000 Operation

4.11 Checking the HTF Level

When

Prerequisites

Procedure

If low

 Before leaving for the job site, or  Before beginning operation at the job site

 The machine is level.  The machine is cool.

The Heat Transfer Fluid (HTF) level must be between the marks on the sightglass (c).

If the HTF level is low, HTF must be added. Filling the HTF reservoir requires electric power to the machine and knowledge of the machine’s operation. Familiarize yourself with the function of the machine’s controls, then see topic Filling the HTF Reservoir for detailed instructions.

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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

temperature °F (°C)

Below 5 (-15)

Generator-powered Shore-powered

50-50 blend of #2 diesel

and #1 diesel, plus

additives

50-50 blend #2 diesel and

K1 kerosene, plus

additives

100% #1 diesel plus

additives

100% K1 kerosene,

plus additives

70-30 blend of #2 diesel and #1 diesel, plus additives

5 to 25 (-15 to -4)

Above 25 (-4) Winter-blend diesel

70-30 blend of #2 diesel and K1 kerosene,

plus additives

NOTICE: Do not use B20 or any other type of biodiesel fuel in this machine.

CAUTION

Fire hazard. f Do not use gasoline, crankcase oil, or any oil containing gasoline.

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E 3000 Operation

4.13 Refueling the Machine

Requirements

Procedure

 Machine shut down  Machine level with the ground  Diesel fuel supply

Perform the procedure below to refuel the machine.

Note: On models with generators, it is not necessary to fill the generator’s fuel tank. Both the burner and the generator use the machine’s fuel tank.

1. Lift the lever (a) on the fuel cap.

wc_gr008446

2. Rotate the lever counterclockwise until it stops.

wc_gr008447

3. Remove the fuel cap from the tank.

wc_gr008448 wc_gr008599

4. Fill the tank with the appropriate grade of fuel for the weather conditions until the gauge (b) reads full. Leave room within the tank for possible fuel expansion.

CAUTION

Fire and health hazard. Fuel expands when heated. Expanding fuel in a overly-full tank can lead to spills and leaks.

f Do not overfill the fuel tank.

5. Reinstall the fuel cap.

Result

wc_tx001951gb.fm

The procedure to refuel the machine is now complete.

Operation E 3000

4.14 Positioning the Machine

DANGER

Asphyxiation hazard. Exhaust gas from the burner contains carbon monoxide, a deadly poison you cannot see or smell. Exposure to carbon monoxide can kill you in minutes. f Position the machine so that burner exhaust will not enter any nearby

structures.

WARNING

Fire hazard. Do not move the machine while it is running. f Shut down the machine before moving or repositioning it.

WARNING

Fire hazard. Machines positioned on a hill or an incline may slide, break away or roll over. f Do not position the machine on a hill or an incline.

CO Alarms

Requirements

WARNING

Explosion and fire hazard. Risk of severe injury or death. f Do not operate the machine near flammable vapors, fuels, or combustibles.

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.

Install battery-operated CO alarms or plug-in CO alarms with battery backup, according to the manufacturer’s instructions. CO alarms should be certified to the requirements of the latest safety standards (UL 2034, IAS 6-96, or CSA 6.19.01). Test the CO alarm batteries monthly.

Position the machine:

 so that burner exhaust will not enter nearby structures.  so that the machine does not block traffic.  so that the machine is not close to any combustible material or flammable vapor .  so that all of the machine’s access doors/panels may be accessed.  so that HTF hoses do not pose tripping hazards, and so the HTF hoses cannot

be damaged by machines or other equipment on the job site.

This procedure continues on the next page.

wc_tx001951gb.fm

E 3000 Operation

Continued from the previous page.

Procedure

Result

Perform the following procedure to position the machine.

1. Place the machine near the application area (a) on solid, stable, and level ground.

E TI N

TIE DOW

TIE DOWN

DOW

wc_gr008529

2. For machines with trailers, install chocks (b) under the wheels.

The machine is now properly positioned.

E TI WN DO

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Operation E 3000

4.15 Pre-Starting Checks

Requirements

Checks

 Machine properly positioned  Power connected to the machine

Before starting the machine, check the following items:

Fuel System

Fuel sight gauge valve

(a)

f Check that the fuel sight

gauge valve is open.

Fuel sight gauge

(b)

f Check that the fuel tank is

full.

Quick connects

(d)

f Check that the quick-con-

nect couplings are secure.

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Heat Transfer Fluid (HTF) System

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wc_tx001951gb.fm

E 3000 Operation

Suction valve (#2)

f Check that suction valve (#2)

is open.

HTF fill valve

(#3)

f Check that HTF fill valve (#3)

is closed and locked with the locking pin.

NOTICE:

remain closed and locked during normal operation. An open HTF fill valve will cause HTF leakage.

The HTF fill valve must

HTF sight gauge (c)

f Check that the HTF level is

within the operating range.

NOTICE:

with low HTF will damage the pumps.

Starting the machine

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HTF Hose connections (e)

f Check that all HTF hose

quick-connects are secure.

Operation E 3000

Hydronic heater

(f)

f Inspect for signs of exhaust

leaks. See topic

Replacing the Rope Gasket.

Inspecting/

Genset (g) (if equipped)

f Check oil level. See topic

Checking the Engine Oil.

f Inspect for signs of fuel and

exhaust leaks

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Result

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The machine is ready to have power applied.

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E 3000 Operation

4.16 Connecting Power to the Machine

Prerequisites

Extension cords

Procedure

 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.

f Do not use undersized extension cords.

Restrictions for extension cords:

 Use only 3-wire type extension cords with heavy-duty plugs.  The maximum length of extension cord usage per circuit is 30 m (100 ft).  Use 12-gauge extension cords for lengths up to 15 m (50 ft).  Use 10-gauge extension cords for lengths up to 30 m (100 ft).

Follow the procedure below to connect power to the machine.

1. Move both circuit breaker switches (a and b) to the OFF position.

POWER 2

POWER 1

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2. Connect the main power cords (c) to a properly-rated power source or to the generator (d) if included.

Result

Power has now been connected.

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Operation E 3000

4.17 Starting and Stopping the Generator

Background

Starting

Only general starting and stopping procedures for the gene rator are included in this manual. See the generator manufacturer’s operation manual for detailed procedures.

Perform the procedure below to start the generator.

1. Move the circuit breaker switches on the genset to the OFF position.

2. Prime the fuel system if needed. The fuel system will need to be primed if:

 Fuel system has run dry  Fuel system has been drained  The fuel filter has been changed  The genset has not been run for several weeks

f To prime the fuel system: Press and hold the control switch in the “S top / Prime”

position. The fuel pump will start two seconds after the control switch is initially placed in the “Stop / Prime” position. Continue holding the control switch for at least one minute.

Start /

Preheat

Stopping

Stop /

Prime

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3. Press and hold the control switch in the “Start / Preheat” position. The genset will first preheat (for up to 15 seconds depending on how cold it is). Then, the starter will engage and the engine will start.

NOTICE: Do not crank the engine for more than 30 seconds at a time. Wait at least two minutes before cranking the engine again.

Perform the procedure below to stop the genset.

1. Move the generator circuit breakers to the OFF position.

2. Allow the genset to run two minutes to cool down.

3. Press the control switch to the “Stop / Prime” position.

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E 3000 Operation

4.18 Applying Power to the Machine

Requirements

Procedure

 Pre-starting checks have been completed  Power connected to the machine

Follow the procedure below to apply power to the machine.

1. Move both circuit breaker switches (a) to the ON position.

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2. Check that the indicator lights of both GFCIs (b) are off. Press the “RESET” button of the GFCI if its indicator light is ON.

3. Check that the low-level-fault indicator light (c) is OFF. If this light is ON, add Heat Transfer Fluid (HTF) to the reservoir. See topic Filling the HTF Reservoir.

Result

4. Check that the displays of the temperature controller (d) illuminate. If the displays of the temperature controller do not illuminate, there is a problem with the GFCI 1 or with the wiring to the temperature controller. Disconnect the main power supply and rectify the problem before continuing.

The machine is ready for operation.

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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

Procedure

 HTF reservoir full  Machine powered up

Follow the procedure below to preheat the HTF.

1. Use the up and down arrows (a) on the temperature controller to set the HTF temperature to 100°F (40°C). This is the set point temperature.

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2. Move the burner ON-OFF switch (b) to the ON position. The following sequence occurs:

a.The burner motor starts after a 5-second delay. b.The burner fires after a 15-second delay. c.The burner will operate, with little or no visible exhaust smoke, until the HTF

reaches the set point temperature, at which time, the burner will stop firing.

d.The burner will re-fire if the set point temperature is increased or the

temperature of the HTF falls below 100°F (40°C).

Note: The temperature of the HTF is displayed (b) in red.

Result

When the temperature controller displays “100.0” (b) the HTF is preheated.

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E 3000 Operation

4.20 Initiating HTF Flow

Requirements

Procedure

 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. f Wear gloves when handling hot hoses or hot plumbing components.

Note: If you are using accessories, see Chapter “Accessories”.

Follow the procedure below to initiate HTF flow.

1. Close and lock valve #3. This is the fill valve.

2. Open valve #2. This is the suction valve.

3. Open valve #4 and valve #6. These are the hose reel supply valves.

This procedure continues on the next page.

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Operation E 3000

Continued from the previous page.

4. Move the left pump ON-OFF switch (d) to the ON position.

75

180

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.

NOTICE: If the HTF reaches 170 psi (11.7 bar) after only a second or two of operation, there is a problem. Shut down the machine and rectify the problem before continuing.

 Once flow is established, pressure should be: 125–140 psi (8.6–9.6 bar).  When the HTF is warm, operating pressure should be: 90–110 psi (6.2–7.6

bar).

6. Check the HTF flow indicator (f). The flow indicator should be spinning. If it is not, there is a problem. Shut down the machine and rectify the problem before continuing.

7. Repeat steps 4–6 for the right pump.

Result

HTF is now flowing.

4.21 Setting the Operating Temperature

Operating temperature

Once the HTF is preheated, set the temperature controller to the operating temperature. Use the chart below as a guide.

Operation type Recommended Temperature Setting

Ground thawing Concrete curing

Air heating

80°C (180°F) 7°C (20°F) above the desired temperature of the con-

crete 80°C (180°F)

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E 3000 Operation

4.22 Unwinding and Positioning the Hoses

Requirements

Procedure

 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. f Wear gloves when handling hot hoses and plumbing components.

Follow the procedure below to unwind and position the hoses.

1. Rotate the T-handle (a) counter-clockwise to unlock it.

Result

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wc_gr008535

2. Pull the hose (b) off the reel by hand and place it in the application area. See topic Hose Spacing Guidelines for hose spacing recommendations based on application.

The hose is now positioned and the machine is operating. NOTICE: The machine must be periodically monitored during operation to ensure

system efficiency. See topic Monitoring the Operating Parameters.

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Operation E 3000

4.23 Hose Spacing Guidelines

Background

Hose spacing diagram

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.

Refer to the diagram and table below when placing hoses in the application area.

Note: Adjustments may be necessary to achieve maximum efficiency.

Application Distance (d) Description

Frost prevention 91.5 cm (36 in.) Prevents frost in the application area. Concrete curing 61 cm (24 in.) Allows concrete to cure. Excavation thaw 61 cm (24 in.) Partially thaws the ground for excavation. Compaction thaw 45.7 cm (18 in.) Completely thaws the ground for compaction. Accelerated thaw 30.5 cm (12 in) Up to 50% faster than compaction thaw.

Note: To increase heat penetration, cover the hoses with a plastic vapor barrier and two layers of insulated blankets. For concrete curing, cover the concrete with plastic, place the hoses on top of the plastic, then cover the hoses with two layers of insulated blankets.

Note: The hoses may be positioned vertically along concrete framing walls for curing applications. Contact Wacker Neuson Application Support for more information.

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E 3000 Operation

4.24 Monitoring the Operating Parameters

Background

Parameters

Monitor the machine while it is operating to ensure safe and efficient operation.

Monitor the following parameters every 8–24 hours.

Parameter Notes

Fuel level Add fuel as needed. HTF level Add HTF as needed. HTF operating pressure Operating pressure: 90–110 psi.

If operating pressure is higher than 110 psi, check for kinked hoses. If operating pressure is less that 90 psi, check HTF level.

HTF return temperature The HTF return temperature tells you how much heat is

being transferred. It can also tell you when a thawing process 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.

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Operation E 3000

4.25 Rewinding the Hoses

Requirements

Procedure

 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. f Wear gloves when handling hot hoses and plumbing components.

Perform the procedure below to rewind the hose.

Note: Turn the pump ON. Turning the pump on—to circulate warm HTF through the hose—will aid in handling of the hose.

1. Turn the T-handle (a) counterclockwise to unlock the hose reel.

wc_gr008530

2. Remove the foot pedal (b) and place it on a firm, flat, and dry surface.

3. Move the hose rewind ON-OFF switch (c) to the RIGHT or LEFT position depending which reel you are working with.

Note: The rewind motor will start but will not rotate the hose reel until the clutch is engaged.

wc_gr008531

wc_gr008532

4. Press down on the foot pedal to engage the clutch. The hose reel will rotate.

wc_gr008533

5. Guide the hose evenly onto the hose reel as it rotates.

This procedure continues on the next page.

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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.

Result

wc_gr008535

wc_gr008534

8. Engage the hose reel brake by turning the T-handle (a) clockwise.

9. Return the foot pedal (b) to its storage location.

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10.Turn the pump off.

11.Move the hose rewind ON-OFF switch (c) to the OFF position.

The hoses are now wound onto the hose reel and the machine is ready to be shut down. See topic Shutting Down and Packing Up the Machine.

wc_gr008532

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Operation E 3000

4.26 Shutting Down and Packing Up the Machine

Shutting down

Perform the procedure below to shut down the machine.

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.

b1 b2

LEFT

PUMP

4. Move the pump ON-OFF switches (b

RIGHT PUMP

wc_gr008536

and b2) to the OFF position.

5. Move the circuit breaker ON-OFF switches (e) to the OFF position.

The machine is now shut down and ready to be packed up.

Packing up the machine

Perform the following procedure to pack up the machine.

1. Disconnect and store all accessories.

2. Disconnect power from the machine.

3. Close and lock all doors.

Result

The machine is now ready to be stored.

wc_gr008537

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E 3000 Operation

4.27 Resetting a Low HTF Fault

Requirements

Background

Procedure

 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.

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 capacity. During a low HTF level condition the following occurs:

 The control panel low level fault light illuminates  Power is cut to the burner  Power is cut to the pumps  The low-level shut-down device “LOW WATER” light illuminates

Follow the procedure below to reset a low HTF fault.

1. Move the burner switch to the OFF position.

2. Move the pump switches to the OFF position.

3. Clean the fill hose.

4. Remove the locking pin, then open valve #3 and close valve #2 simultaneously.

5. Place the open end of the fill hose (a) into a container full of HTF.

6. Open valve #6 (right hose reel supply valve).

This procedure continues on the next page.

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wc_gr008538

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. Doing so may damage the machine.

8. Press and release the “RESET” button (d) on the low-level shut-down device.

The following will occur:

 The “POWER” (green) (f) and “LOW WATER” (red) (e) lights will blink for fif-

teen seconds while the low-level shut-down device performs a self-diagnostic test.

 After 15 seconds, the “LOW W ATER” light will go out—the “POWER” light will

stay on.

 The low HTF level indicator will go out.  Power will be returned to the pumps.  Power will be returned to the burner.

9. Move the right pump switch to the ON position (I) and continue to fill the HTF reservoir until the HTF level is between the two marks on the HTF reservoir sightglass.

NOTICE: Do not overfill the HTF reservoir. Doing so may damage the machine.

This procedure continues on the next page.

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E 3000 Operation

Continued from the previous page.

10.Move valve #3 to the normal position.

1 1.Remove the fill hose from the HTF cont ain er and allow any HTF within the ho se

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.

13.Open valve #2 and close valve #3 simultaneously.

Result

The low HTF level fault has been reset and the HTF reservoir has now been filled. You may now resume operation of the machine.

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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. f Wear gloves when handling hot hoses and hot plumbing components.

Precautions

Cleaning

Using

 Do not join or separate quick-connect couplings when the pressure gauge

indicates that the system is pressurized.

 Do not join or separate quick-connect couplings when the HTF temperature is

above 48°C (120°F).

 Do not use damaged quick-connect couplings.  Do not use dirty or contaminated quick-connect couplings.  Do not lubricate the quick-connect couplings.

Follow the procedure below to clean the quick-connect couplings. Do so before and after each use.

1. Clean both the male

(a)

and female coupling

(b)

by rinsing each with clean water.

2. When the couplings are clean, inspect seals and gaskets and replace them if necessary.

3. After cleaning the couplings, install cap s or protective covers on the couplings to protect them.

Follow the procedures below to use the quick-connect couplings.

1. Pull back and hold the locking collar (c) on the female coupling (b).

2. Insert the male coupling (a) into the female coupling.

3. Release the locking collar. The couplings will lock together.

To release the couplings:

1. Pull back and hold the locking collar (c) on the female coupling (b).

2. Pull the male coupling from the female coupling.

3. Release the locking collar.

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E 3000 Operation

4.29 Operating States of the Beckett Burner Controller

Operating

10 30

Ignition

State

Standby

carryover

Run

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

Valve-on

delay

(pre-time)

Trial-for-

ignition

enters the standby state in which it will remain until there is a call for heat or power is disconnected.

When the setpoint of the temperature controller is set to a temperature higher than that of the heat transfer fluid, the output contacts of the temperature controller close, completing a circuit between the two te rminals labeled “T” of the burner control. This is the call for heat. The burner control enters the valve-on-delay state.

The valve-on-delay state lasts 15 seconds. During this state:

 Power is sent to the burner motor/fuel pump.  Power is sent to the electrodes.  If the cad cell detects flame at the end of the valve-on-delay state, the

burner control goes into the lockout state.

The trial-for-ignition state immediately follows the valve-on-delay state. During this state:

 The fuel shut-off valve is opened (energized).  Pressurized fuel atomizes at the burner nozzle.  The atomized fuel is ignited by the electrodes.  The burner fires and the flame is monitored by the cad cell.  If flame is detected, the burner control moves to the ignition carryover

state.

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If flame is not detected within 15 seconds:

 The burner control enters the lockout state.  Power is disconnected from the fuel shut-off valve, electrodes, and

the burner motor.

Operation E 3000

State Action or Function

Ignition

carryover

The ignition carryover state starts as soon as the flame is established. 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.

When the ignition carryover state has elap sed:

 The ignition transformer is shut off.  The burner control enters the run state.

If the flame is lost during the ignition carryover state:

 If the lockout time has not expired, the burner control returns to trial-

for-ignition state.

 If the lockout time has expired, the burner control enters the recycle

mode.

Run The run state starts and continues once the ignition carryover state has

elapsed. During this state:

 The fuel shut-off valve is open (energized).  Pressurized fuel atomizes at the burner nozzle.  The flame is monitored by the cad cell.

When the setpoint is reached (call for heat satisfied), the burner control enters the burner-motor-of f delay state.

If the flame is lost during the run state:

 The burner control enters the recycle mode.

Burner-motor-

off-delay

The burner-motor-off-delay state starts immediately after the setpoint is reached, i.e., the call for heat has been satisfied. The time of this state is 30 seconds. During this state:

 The output contacts of the temperature controller open, interrup ting

the circuit between terminals labeled “T”.

 The fuel shut-off valve closes (de-energizes).  The burner motor runs until the burner-motor-off delay expires, then

the burner motor turns off.

 The burner control returns to the idle mode.

If the cad cell detects flame during the burner-motor-off-delay state:

 The burner control goes into the standby state.

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E 3000 Operation

Lockout

The lockout state is described below.

State Action or Function

Lockout

The burner will enter the lockout state for the following reasons:

 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.  Relay check failure.

Note: The burner control cannot reset by interrupting the voltage.

During the lockout state:

 The burner will not fire.  The red reset button / lockout light on the burner control will

flash during a soft lockout condition.

 The reset button / lockout light will remain on continuously

during a hard lockout condition.

 The burner fault light on the control panel will illuminate.

To clear the soft lockout fault so a restart can be attempted, press and release the reset button. Note: After the third attempt

to manually clear the lockout fault, the burner control will enter the hard lockout mode. To clear the hard lockout, press and hold the reset button for 15 seconds.

Recycle

Yellow

pump prime

The recycle mode is described below.

State Action or Function

Recycle The burner will enter the recycle mode if the flame is lost while

the burner is firing. During the recycle mode:

 The burner control shuts down the burner.  The burner control enters a 60-second delay, then repeats

the ignition sequence.

 The green flame / recycle light on the control panel flashes.  The burner control attempts to recycle each time the flame is

lost, up to three times. If flame is not established after the third time, the burner control enters the hard lockout state.

To clear the hard lockout fault so a restart can be attempted, press and hold the reset button for 15 seconds.

Reset button / lockout

Green

flame / recycle

Red

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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. During this mode:

 Power is sent to the burner motor/fuel pump.  Power is sent to the electrodes.  The cad cell is disregarded.  The yellow pump prime light illuminates.

To enter the pum p pr ime mo de :

1. Prepare the burner for priming. Do not allow oil to spray

into a hot combustion chamber.

 Attach a hose over the bleed port fitting.  Fully open the pump bleed valve.  Use a suitable container to collect the purged oil.

2. Set the temperature controller so there is a call for heat.

3. After the burner starts, press and hold the reset button for 15 seconds until the yellow light turns on, then release the reset button. The yellow light will turn off, the burner control powers down the burner, and the burner will then start up again. At burner startup, press and release the reset button to enter the pump prime mode. The yellow light will turn on.

To exit the pump prime mode, do one of the following:

 Set the temperature controller so there is no longer a call for

heat and press the reset button for at least 1 second. The burner control will return to the standby state.

 Wait four minutes for the pump prime mode to time out. The

burner control will return to the standby state. The yellow light will turn off.

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E 3000 Operation

Notes

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Accessories E 3000

5 Accessories

5.1 Available Accessories

To increase the machine’s capabilities and capacities, the following Wacker Neuson accessories are available.

Configurations

Ref Description Ref. Description

Hose Handling System (HHS3002)

Heat Exchanger (HX 50)

Heat Exchanger (HX 100)

Heat Exchanger (HX 200)

Insulation blanket

1-2 Adapter

2-1 Adapter

Accessory hoses (various lengths)

Single (SPP) or Dual Pump Pack (DPP)

Auxiliary Pump Panel (APP) (power adapter)

These accessories allow the following application configurations:

 Combining your parent machine with Heat XCHANGERS allows it to heat air.  Combining your parent machine with a DPP and HHS increases the ground

heating, thawing, and curing capacities of the parent machine.

 Covering the heat transfer hoses with insulation blankets increases heat

retention and penetration.

 The 1–2 and 2–1 adapters and accessory hoses allow the accessories to be

properly connected to your parent machine.

For compatibility and configuration information, continue reading.

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E 3000 Accessories

5.2 Expanding the Surface Heating Capacity

Background

Estimated capacities

Option 1

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. For more information, contact W acker Neuson Application Support.

The machine is capable of the following when utilizin g the expansion configuration s illustrated below.

Application

Option

Description

1 HHS and 1 DPP

2 HHS and 2 DPP

m (ft2)

m (ft2) Not applicable

Thaw Cure Frost Prevention

550 (6000)

1110 (12,000)

1670 (18,000)

2500 (27,000)

E 3000 combined with one HHS 3002 (a) and one DPP (b).

Option 2

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wc_gr008539

E 3000 combined with two HHS 3002’s (a) and two DPP’s (b). Note: This configuration requires installing an Auxilliary Pump Panel for power

protection. See topic “Mounting the Auxiliary Pump Panel.”

wc_gr008540

For more information regarding setup of these configurations, continue reading.

Accessories E 3000

5.3 E xpanded Operation Usin g One HHS 3002 and One DPP

Requirements

Procedure

 Machine stopped  One HHS 3002 Hose Handling System  One DPP Dual Pump Pack

Perform the procedure below to expand the machine with one Hose Handling System (HHS) and one Dual Pump Pack (DPP).

1. Position the E 3000 near the application area.

2. Position the DPP (a) near the application area.

3. Unwind and position the hose (b) from the left reel of the E 3000 within the application area.

4. Unwind and position the hose (c) from the right reel of the E 3000 within the application area.

5. Unwind and position the hose loop 1 (d) from the HHS 3002 (f) within the application area.

a.Connect the male quick-connect to the return port (g). b.Connect the female quick-connect to the DPP (a).

6. Unwind and position the hose loop 2 (e) from the HHS 3002 (c) within the application area. Place the HHS 3002 frame in a safe place.

a.Connect the male quick-connect to the return port (h). b.Connect the female quick-connect to the DPP (a).

Result

7. Connect the leader hose of the DPP to the accessory supply port (#1).

8. Connect the electric cord of the DPP to the Auxiliary Pump Panel. See topic Mounting the Auxiliary Pump Panel.

The machine is now ready for expanded operation.

This procedure continues on the next page.

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E 3000 Accessories

Continued from the previous page.

wc_gr008541

Ref Description Condition

#1 Pump pack supply valve 1 Open after connection #4 Right HTF supply valve Open after connection #5 Cross connect valve Closed #6 Left HTF supply valve Open after connection #7 Pump pack supply valve 2 Closed (no connections)

a DPP Connected to E 3000 and HHS 3002 b Hose loop from left reel Placed in application area

c Hose loop from right reel Placed in application area d HHS 3002 hose loop 1 Placed in application area e HHS 3002 hose loop 2 Disconnected from HHS 3002 hose loop 1

and placed in application area

f HHS 3002 frame Placed in safe location g Return port Used for HSS 3002 loop 1 h Return port Used for HHS 3002 loop 2

x Leader hose Used to connect DPP to E 3000

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Accessories E 3000

5.4 E xpanded Operation Usin g Two HHS 3002 and Two DPP

Requirements

Procedure

 Machine stopped  Two HHS 3002 Hose Handling Systems  Two DPP Dual Pump Packs  Two 2-1 adapters

Perform the procedure below to expand the machine with two Hose Handling Systems (HHS) and two Dual Pump Packs (DPP).

1. Position the E 3000 near the application area.

2. Position both DPP (a and m) near the application area.

3. Unwind and position the hose (b) from the left reel of the E 3000 within the application area.

4. Unwind and position the hose (c) from the right reel of the E 3000 within the application area.

5. Connect one 2-1 adapter (i) to return port (g).

6. Connect the other 2-1 adapter (j) to return port (h).

7. Unwind and position the hose loop 1 (d) from the first HHS 3002 (f) within the application area.

a.Connect the male quick-connect to the 2-1 adapter (j). b.Connect the female quick-connect to the DPP (a).

8. Unwind and position the hose loop 2 (e) from the HHS 3002 (f) within the application area. Place the HHS 3002 frame in a safe place.

a.Connect the male quick-connect to the 2-1 adapter (j). b.Connect the female quick-connect to the DPP (a).

9. Unwind and position the hose loop 1 (k) from the second HHS 3002 (n) within the application area.

a.Connect the male quick-connect to the 2-1 adapter (i). b.Connect the female quick-connect to the DPP (m).

10.Unwind and position the hose loop 2 (l) from the second HHS 3002 (n) within the application area. Place the HHS 3002 frame in a safe place.

a.Connect the male quick-connect to the 2-1 adapter (i). b.Connect the female quick-connect to the DPP (m).

11.Connect the leader hose of the DPP (a) to the accessory supply port (#1).

12.Connect the leader hose of the DPP (m) to the accessory supply port (#7).

13.Connect the electric cord of the first DPP to the Auxiliary Pump Panel. See topic Mounting the Auxiliary Pump Panel.

14.Connect the electric cord of the second DPP to the duplex receptacle of the E 3000.

Result

The machine is now ready for expanded operation.

This procedure continues on the next page.

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E 3000 Accessories

Continued from the previous page.

This procedure continues on the next page.

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k l d

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Accessories E 3000

Continued from the previous page.

Ref Description Condition

a First DPP Connected to E 3000 and HHS 3002 b Hose loop from left reel Placed in application area

c Hose loop from right reel Placed in application area d First HHS 3002 hose loop 1 Placed in application area e First HHS 3002 hose loop 2 Disconnected from first HHS 3002 hose loop

1 and placed in application area

f First HHS 3002 frame Placed in safe location g Return port Used for HSS 3002 loop 1 h Return port Used for HHS 3002 loop 2

i / j 2-1 adapter Connected to return port

k Second HHS 3002 hose loop 1 Placed in application area

l Second HHS 3002 hose loop 2 Disconnected from second HHS 3002 hose

loop 1 and placed in application area

m Second DPP Connected to E 3000 and HHS 3002

n Second HHS 3002 frame Placed in safe location

x First DPP leader hose Connected to E 3000 and HHS 3002 y Second DPP leader hose Connected to E 3000 and HHS 3002

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E 3000 Accessories

5.5 Mounting and Connecting the Auxiliary Pump Panel

Prerequisites

Background

Guidelines

 Machine shut down  Power disconnected

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. This power cut-off protects the pumps from damage.

Follow the guidelines below when mounting the APP. Refer to the diagram below.

 Install inside the machine, near the main control panel (a).  Install using included hardware (b).

This procedure continues on the next page.

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Accessories E 3000

Continued from the previous page.

Electrical connections

After mounting, carry out the steps below to complete the electrical connections.

1. Connect the DIN leader (a) from the main control panel to the corresponding DIN leader on the APP (b).

2. Connect a properly-rated extension cord (c) to the power cord (d) on the APP.

3. Connect the Pump Pack power cord (f) to the APP power adapter (e).

Result

The APP is now mounted and connected. Continue with normal operation.

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E 3000 Accessories

5.6 Using Heat Exchangers to Heat Air

Background

Configuration requirements

The E 3000 can be combined with W acker Neuson HX 50, HX 100, or HX 200 Heat Exchangers to convert the heating application from surface to air.

In order to connect Heat Exchangers to the machine, additional accessories (Single Pump Packs (SPP), Dual Pump Pack (DPP), or Auxiliary Pump Panel (APP) may be required to support the additional load on the machine’s systems. Use the chart below to determine what components may be required.

NOTICE: Use care when adding accessories; failure to adhere to these requirements may damage your machine.

Additional components required

Heat Exchanger

Model

HX 50

Qty

SPP DPP

1-2

Adapter

2-1

Adapter

APP

1————— 2————— 3—— 1 1— 4—— 1 2— 51—231

Limitations

61—341

HX 100

1————— 2————— 31—1—1

HX 200

1————— 2— 1— 1 1

 Maximum run (horizontal distance from HX to machine): 228 m (750 ft)  Maximum rise (vertical distance of HX above machine): 76 m (250 ft)  Maximum run at maximum rise: 215 m (707 ft)

Note: The farther the HX is positioned from the pa rent machine, the more heat will be lost through the hose. This may affect HX performance.

0 – 76 m (250 ft)

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0 – 215 m (707 ft)

0 – 228 m (750 ft)

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Accessories E 3000

5.7 Connecting Six HX 50 Heat Exchangers

Requirements

Connect adapters

Connect the SPP

 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.)

Perform the procedure below to connect the Heat Exchanger to the machine.

1. Connect a 2-1 adapter (x) to the left return plumbing rack (LR).

2. Connect a 2-1 adapter (y) to 2-1 adapter (x).

3. Connect a 1-2 adapter (z) to left accessory supply (LS).

4. Connect a 2-1 adapter (w) to the right return plumbing rack (RR).

5. Connect a 2-1 adapter (u) to 2-1 adapter (w).

6. Connect a 1-2 adapter (v) to right accessory supply (RS).

1. Position the SPP (g) near the machine.

2. Connect hose (i) to the supply port of the SPP and to valve #1 of the machine.

3. Connect a 1-2 adapter (h) to the outlet port of the SPP.

Connect the HX hoses

Complete the installation

4. Open valve #1.

1. Position the Heat Exchangers (a thru f) within the space to be heated.

2. Connect Heat Exchanger (a) to 1-2 adapter (z) and 2-1 adapter (x).

3. Connect Heat Exchanger (b) to 1-2 adapter (z) and 2-1 adapter (y).

4. Connect Heat Exchanger (c) to 1-2 adapter (v) and 2-1 adapter (y).

5. Connect Heat Exchanger (d) to 1-2 adapter (v) and 2-1 adapter (u).

6. Connect Heat Exchanger (e) to 1-2 adapter (h) and 2-1 adapter (u).

7. Connect Heat Exchanger (f) to 1-2 adapter (h) and 2-1 adapter (w).

1. Insulate the supply and return hoses.

2. Connect the Heat Exchangers to the appropriate electrical source.

3. Connect the SPP power cord to the APP.

4. Open cross-connect valve #5.

5. Close valve #4 and valve #6.

This procedure continues on the next page.

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E 3000 Accessories

Continued from the previous page.

Run the machine

NOTICE: Only start the pumps when the Heat Exchang ers are conne cted. Starting the pumps when the Heat Exchangers are not connected will cause excess system pressure which may damage the pumps.

1. Start the E 3000 and operate it with the temperature controller set to 180°F (80°C).

2. Turn on the Heat Exchangers and adjust the thermostats as desired.

LR RR

2-1

SPP

2-1

1-2

2-1

1-2

APP

2-1

1-2

HX 50 HX 50 HX 50 HX 50 HX 50 HX 50

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Accessories E 3000

5.8 Connecting Five HX 50 Heat Exchangers

Requirements

Connect adapters

Connect the SPP

 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.)

Perform the procedure below to connect the Heat Exchangers to the machine.

1. Connect a 2-1 adapter (x) to the left return plumbing rack (LR).

2. Connect a 2-1 adapter (y) to 2-1 adapter (x).

3. Connect a 1-2 adapter (z) to left accessory supply (LS).

4. Connect a 2-1 adapter (w) to the right return plumbing rack (RR).

5. Connect a 1-2 adapter (v) to right accessory supply (RS).

1. Position the SPP (g) near the machine.

2. Connect hose (i) to the supply port of the SPP and to valve #1 of the machine.

3. Open valve #1.

Connect the HX hoses

Complete the installation

Run the machine

1. Position the Heat Exchangers (a thru e) within the space to be heated.

2. Connect Heat Exchanger (a) to 1-2 adapter (z) and 2-1 adapter (x).

3. Connect Heat Exchanger (b) to 1-2 adapter (z) and 2-1 adapter (y).

4. Connect Heat Exchanger (c) to 1-2 adapter (v) and 2-1 adapter (y).

5. Connect Heat Exchanger (d) to 1-2 adapter (v) and 2-1 adapter (w).

6. Connect Heat Exchanger (e) to SPP and 2-1 adapter (w).

1. Insulate the supply and return hoses.

2. Connect the Heat Exchangers to the appropriate electrical source.

3. Connect the SPP power cord to the APP.

4. Open cross-connect valve #5.

5. Close valve #4 and valve #6.

NOTICE: Only start the pump s when the Heat Exchan gers are connected . Starting the pumps when the Heat Exchangers are not connected will cause excess system pressure which may damage the pumps.

1. Start the E 3000 and operate it with the temperature controller set to 80°C.

2. Turn on the Heat Exchangers and adjust the thermostats as desired.

Result

The Heat Exchangers have now been connected and are operating.

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E 3000 Accessories

LR RR

2-1

SPP

2-1

1-2

APP

2-1

HX 50 HX 50 HX 50 HX 50 HX 50

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Accessories E 3000

5.9 Connecting Four HX 50 Heat Exchangers

Requirements

Connect adapters

Connect the HX hoses

Complete the installation

 Machine stopped  Four HX 50 Heat Exchangers  Two 2-1 adapters  Two 1-2 adapters

Perform the procedure below to connect the Heat Exchangers to the machine.

1. Connect a 2-1 adapter (x) to the left return plumbing rack (LR).

2. Connect a 1-2 adapter (z) to left accessory supply (LS).

3. Connect a 2-1 adapter (y) to the right return plumbing rack (RR).

4. Connect a 1-2 adapter (v) to right accessory supply (RS).

1. Position the Heat Exchangers (a thru d) within the space to be heated.

2. Connect Heat Exchanger (a) to 1-2 adapter (z) and 2-1 adapter (x).

3. Connect Heat Exchanger (b) to 1-2 adapter (z) and 2-1 adapter (x).

4. Connect Heat Exchanger (c) to 1-2 adapter (v) and 2-1 adapter (y).

5. Connect Heat Exchanger (d) to 1-2 adapter (v) and 2-1 adapter (y).

1. Insulate the supply and return hoses.

2. Connect the Heat Exchangers to the appropriate electrical source.

Run the machine

Result

3. Open cross-connect valve #5.

4. Close valve #4 and valve #6.

NOTICE: Only start the pump s when the Heat Exchan gers are connected . Starting the pumps when the Heat Exchangers are not connected will cause excess system pressure which may damage the pumps.

1. Start the E 3000 and operate it with the temperature controller set to 180°F (80°C).

2. Turn on the Heat Exchangers and adjust the thermostats as desired.

The Heat Exchangers have now been connected and are operating.

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E 3000 Accessories

LR RR

2-1

1-2

HX 50 HX 50 HX 50 HX 50

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Accessories E 3000

5.10 Connecting Three HX 50 Heat Exchangers

Requirements

Connect adapters

Connect the HX hoses

Complete the installation

 Machine stopped  Three HX 50 Heat Exchangers  One 2-1 adapter  One1-2 adapter

Perform the procedure below to connect the Heat Exchangers to the machine.

1. Connect a 2-1 adapter (x) to the left return plumbing rack (LR).

2. Connect a 1-2 adapter (z) to left accessory supply (LS).

1. Position the Heat Exchangers (a thru c) within the space to be heated.

2. Connect Heat Exchanger (a) to 1-2 adapter (z) and 2-1 adapter (x).

3. Connect Heat Exchanger (b) to 1-2 adapter (z) and 2-1 adapter (x).

4. Connect Heat Exchanger (c) to right accessory supply (RS).

5. Connect Heat Exchanger (c) to return plumbing rack (RR).

1. Insulate the supply and return hoses.

2. Connect the Heat Exchangers to the appropriate electrical source.

3. Open cross-connect valve #5.

Run the machine

Result

4. Close valve #4 and valve #6.

NOTICE: Only start the pump s when the Heat Exchan gers are connected . Starting the pumps when the Heat Exchangers are not connected will cause excess system pressure which may damage the pumps.

1. Start the E 3000 and operate it with the temperature controller set to 180°F (80°C).

2. Turn on the Heat Exchangers and adjust the thermostats as desired.

The Heat Exchangers have now been connected and are operating.

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E 3000 Accessories

LR RR

2-1

1-2

HX 50 HX 50 HX 50

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Accessories E 3000

5.11 Connecting Two HX 50 Heat Exchangers

Requirements

Connect the HX hoses

Complete the installation

Run the machine

 Machine stopped  Two HX 50 Heat Exchangers

1. Position the Heat Exchangers (a and b) within the space to be heated.

2. Connect Heat Exchanger (a) to left accessory supply (LS).

3. Connect Heat Exchanger (a) to return plumbing rack (LR).

4. Connect Heat Exchanger (b) to right accessory supply (RS).

5. Connect Heat Exchanger (b) to return plumbing rack (RR).

1. Insulate the supply and return hoses.

2. Connect the Heat Exchangers to the appropriate electrical source.

3. Cross-connect valve #5 may be open or closed.

4. Close valve #4 and valve #6.

NOTICE: Only start the pump s when the Heat Exchan gers are connected . Starting the pumps when the Heat Exchangers are not connected will cause excess system pressure which may damage the pumps.

1. Start the E 3000 and operate it with the temperature controller set to 180°F (80°C).

Result

2. Turn on the Heat Exchangers and adjust the thermostats as desired.

The Heat Exchangers have now been connected and are operating.

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E 3000 Accessories

LR RR

HX 50 HX 50

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Accessories E 3000

5.12 Connecting One HX 50 Heat Exchanger

Requirements

Connect the HX hoses

Complete the installation

Run the machine

 Machine stopped  One HX 50 Heat Exchanger

1. Position the Heat Exchanger (a) within the space to be heated.

2. Connect Heat Exchanger to left accessory supply (LS).

3. Connect Heat Exchanger to return plumbing rack (LR).

1. Insulate the supply and return hoses.

2. Connect the Heat Exchanger to the appropriate electrical source.

NOTICE: Cross-connect valve #5 may be open or closed. If closed, do not turn on the right pump.

3. Close valve #4 and valve #6.

NOTICE: Only start the pump when the Heat Excha nger is connected. Starting the pump when the Heat Exchanger is not connected will cause excess system pressure which may damage the pump.

1. Start the E 3000 (left pump only) and operate it with the temperature controller set to 180°F (80°C).

2. Turn on the Heat Exchanger and adjust the thermostats as desired.

Result

The Heat Exchanger has now been connected and is operating.

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E 3000 Accessories

HX 50

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Accessories E 3000

5.13 Connecting Three HX 100 Heat Exchangers

Requirements

Connect adapter

Connect the HX hoses

Connect the SPP

 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.)

Perform the procedure below to connect the Heat Exchangers to the machine.

1. Connect a 2-1 adapter (y) to the right return plumbing rack (RR).

1. Position the Heat Exchangers (a thru c) within the space to be heated.

2. Connect Heat Exchanger (a) to left accessory supply (LS).

3. Connect Heat Exchanger (a) to return plumbing rack (LR).

4. Connect Heat Exchanger (b) to 2-1 adapter (y) and right accessory supply (RS).

5. Connect Heat Exchanger (c) to 2-1 adapter (y).

1. Position the SPP near the machine.

2. Connect Heat Exchanger (c) to the SPP (d).

3. Connect hose (e) to the supply port of the SPP and to valve #1 of the machine.

Complete the installation

Run the machine

Result

4. Open valve #1.

1. Insulate the supply and return hoses.

2. Connect the Heat Exchangers to the appropriate electrical source.

3. Connect the SPP power cord to the APP.

4. Open cross-connect valve #5.

5. Close valve #4 and valve #6.

NOTICE: Only start the pump s when the Heat Exchan gers are connected . Starting the pumps when the Heat Exchangers are not connected will cause excess system pressure which may damage the pumps.

1. Start the E 3000 and operate it with the temperature controller set to 180°F (80°C).

2. Turn on the Heat Exchangers and adjust the thermostats as desired.

The Heat Exchangers have now been connected and are operating.

100

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Wacker Neuson E3000, E 3000G, E 3000 LB-G, E 3000 LB Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual