Wacker Neuson E1100 Manuel utilisateur

Taper
Manuel utilisateur
Operator’s Manual
Hydronic Surface Heater
E 1100
E 1100G
Notice d’Emploi
Réchauffeur hydronique de surface
5000188117 02 0114
5000188117
EN / FR
Copyright
notice
© Copyright 2014 by Wacker Neuson Production Americas LLC
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the machine. Any
other type of reproduction is prohibited without express written permission from
Wacker Neuson Production Americas LLC.
Any type of reproduction or distribution not authorized by Wacker Neuson Production
Americas LLC represents an infringement of valid copyrights. Violators will be
prosecuted.
Trademarks
All trademarks referenced in this manual are the property of their respective owners.
Manufacturer
Wacker Neuson Production Americas LLC
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957
www.wackerneuson.com
Original
instructions
This Operator’s Manual presents the original instructions. The original language of this
Operator’s Manual is American English.
5000188093 02 0114
E 1100 Foreword
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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 Americas LLC and must be followed during installation,
operation, and maintenance of the machines.
Machine
documentation
From this point forward in this documentation, Wacker Neuson Production
Americas LLC will be referred to as Wacker Neuson.
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
Refer to the separate Repair Manual for detailed instructions on servicing and
repairing the machine.
If you are missing any of these documents, please contact Wacker Neuson to
order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
Expectations
for
information in
this manual
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.
Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance or safety standards of its
machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson reserves the right to change
any portion of this information without notice.
CALIFORNIA
Proposition
65 Warning
Engine exhaust, some of its constituents, and certain vehicle components, contain
or emit chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
Laws
pertaining to
spark
arresters
NOTICE: State Health Safety Codes and Public Resources Codes specify that in
certain locations spark arresters be used on internal combustion engines that use
hydrocarbon fuels. A spark arrester is a device designed to prevent accidental
discharge of sparks or flames from the engine exhaust. Spark arresters are
qualified and rated by the United States Forest Service for this purpose. In order to
comply with local laws regarding spark arresters, consult the engine distributor or
the local Health and Safety Administrator.
Machine Item Number
E 1100 0620172
E 1100G 0620244
Foreword E 1100
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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.
Table of Contents
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Foreword 3
1 Safety Information 9
1.1 Signal Words Used in this Manual ....................................................... 9
1.2 Machine Description and Intended Use ............................................. 10
1.3 Safety Guidelines for Operating the Machine ..................................... 11
1.4 Safety Guidelines for Lifting the Machine ........................................... 12
1.5 Safety Guidelines for Towing the Machine ......................................... 13
1.6 Safety Guidelines for Operating Combustion Burners ....................... 14
1.7 Safety Guidelines for Operating Gensets ........................................... 15
1.8 Service Safety .................................................................................... 17
2 Labels 20
2.1 Label Locations .................................................................................. 20
2.2 Safety Labels ...................................................................................... 21
2.3 Informational Labels ........................................................................... 24
2.4 Procedural Labels .............................................................................. 26
3 Lifting and Transporting 27
3.1 Lifting the Machine ............................................................................. 27
3.2 Preparing the Machine for Transport on a Truck or Trailer ................ 28
3.3 Transporting the Machine on a Truck or Trailer ................................. 29
3.4 Before Towing Checklist ..................................................................... 30
3.5 Towing the Machine ........................................................................... 31
3.6 Testing the Breakaway System (Electric Brakes) .............................. 32
4 Operation 34
4.1 External Components ......................................................................... 34
4.2 Internal Components .......................................................................... 35
4.3 Control Panel ...................................................................................... 36
4.4 General Sequence of Operation ......................................................... 37
4.5 Checking the HTF Level ..................................................................... 38
4.6 Recommended Fuel ........................................................................... 39
4.7 Refueling the Machine ........................................................................ 40
4.8 Positioning the Machine ..................................................................... 41
4.9 Connecting Power to the Machine ..................................................... 43
4.10 Pre-Starting Checks ........................................................................... 44
4.11 Applying Power to the Machine .......................................................... 45
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4.12 Preheating the HTF .............................................................................46
4.13 Initiating the HTF Flow ........................................................................47
4.14 Unwinding and Positioning the Hoses .................................................49
4.15 Hose Spacing Guidelines ....................................................................50
4.16 Monitoring the Operating Parameters .................................................51
4.17 Rewinding the Hoses ..........................................................................52
4.18 Shutting Down and Packing Up the Machine ......................................54
4.19 Quick-Connect Coupling Usage and Care ..........................................55
4.20 Resetting a Low HTF Fault ..................................................................56
4.21 Operating States of the Beckett Burner Controller ..............................58
5 Accessories 62
5.1 Accessories .........................................................................................62
5.2 Expanding the Surface Heating Capacity ............................................63
5.3 Expanded Operation using One SPP and One HHS 1101 .................65
5.4 Expanded Operation using One DPP and One HHS 2202 .................66
5.5 Using Heat Exchangers (to Heat Air) ..................................................67
5.6 Connecting a HX 100 Heat Exchanger ...............................................68
5.7 Connecting two HX 50 Heat Exchangers ............................................70
6 Burner Setup 72
6.1 Setting/Checking the Electrodes .........................................................75
6.2 Checking/Replacing the Burner Nozzle ...............................................77
6.3 Setting the “Z” Distance .......................................................................79
6.4 Adjusting the Air Settings ....................................................................80
6.5 Setting the Fuel Pressure ....................................................................81
6.6 Removing the Burner ..........................................................................82
6.7 Installing the Burner ............................................................................83
7 Maintenance 84
7.1 Periodic Maintenance Schedule ..........................................................84
7.2 Inspecting the HTF System and the Fuel System ...............................85
7.3 Repairing a Hose .................................................................................86
7.4 Inspecting Electrical Cords ..................................................................88
7.5 Filling the HTF Reservoir .....................................................................89
7.6 Cleaning the HTF Strainer ...................................................................90
7.7 Replacing the Fuel Filter .....................................................................92
7.8 Lubricating the Hose Reel System ......................................................93
7.9 Cleaning the Turbulators and the Exhaust Ducting .............................94
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7.10 Inspecting/Replacing the Rope Gasket .............................................. 96
7.11 Storing the Machine ........................................................................... 97
8 Genset Maintenance 98
8.1 Periodic Maintenance Schedule ......................................................... 98
8.2 Checking the Engine Oil ..................................................................... 99
8.3 Changing the Engine Oil and Oil Filter ............................................. 100
8.4 Checking the Engine Coolant Level ................................................. 102
8.5 Cleaning the Spark Arrester ............................................................. 103
8.6 Replacing the Air Filter Element ....................................................... 104
8.7 Replacing Engine Fuel Filter ............................................................ 105
8.8 Changing Engine Coolant ................................................................ 107
8.9 Genset Shut-Down Codes ................................................................ 109
9 Troubleshooting 113
9.1 Troubleshooting the Machine ........................................................... 113
10 Technical Data 115
10.1 E 1100 .............................................................................................. 115
10.2 Trailer ............................................................................................... 116
10.3 Dimensions ....................................................................................... 116
MSDS: Dowfrost™ HD 50 117
Fuji Temperature Controller 125
11 Schematics 128
11.1 E 1100 Composite Schematic (SN 1538 and higher) ....................... 128
11.2 E 1100 Components ......................................................................... 129
11.3 Burner System Circuit ...................................................................... 132
11.4 Circulation System Circuit ................................................................ 133
11.5 Rewind System Circuit ..................................................................... 134
11.6 E 1100 Composite Schematic (SN 1537 and lower) ........................ 135
11.7 Trailer Plug — Wiring Diagram ......................................................... 136
11.8 Trailer Junction Box — Wiring Diagram ........................................... 137
11.9 Trailer Lights and Brakes — Wiring Diagram ................................... 138
Table of Contents
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E 1100 Safety Information
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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.
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.
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 or 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.
Safety Information E 1100
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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 remain even after protective measures have been taken.
They are called residual risks. On this machine, they may include exposure to:
Heat, noise, and exhaust from the engine or hydronic heater
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Burns from the HTF or radiant heat from the hoses
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
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.
Operator
qualifications
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
Application
area
Be aware of the application area.
Keep unauthorized personnel, children, and pets away from the machine.
Remain aware of changing positions and the movement of other equipment and
personnel in the application area/job site.
Be aware of the application area.
Do not operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
Safety
devices,
controls, and
attachments
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.
Safety Information E 1100
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The machine’s labels are legible.
To ensure safe operation of the machine:
Do not operate the machine if any safety devices or guards are missing or
inoperative.
Do not modify or defeat the safety devices.
Only use accessories or attachments that are approved by Wacker Neuson.
Guidelines for
operator
When operating the machine:
Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
When operating the machine:
Do not operate a machine in need of repair.
Do not smoke near the machine.
Do not disconnect the heat transfer hoses when the pumps are operating or a
burner is firing.
Personal
Protective
Equipment
(PPE)
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
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 weight-
bearing 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 and 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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1.5 Safety Guidelines for Towing the Machine
.
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.
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.
Safety Information E 1100
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1.6 Safety Guidelines for Operating Combustion Burners
Burner safety
When using the machine:
Make sure you have proper certification or licensing required by the locality,
state, or province in which the machine is being installed to connect natural gas
or LP.
Clean up any spilled fuel immediately.
Replace the fuel tank cap after refueling the machine.
Refill the fuel tank in a well-ventilated area.
When using the machine:
Do not fill or drain the fuel tank near an open flame, while smoking, or while the
machine is running.
Do not smoke when refueling the machine.
Do not smoke when connecting natural gas or LP.
Note: Some machines may not be capable of supporting natural gas or LP. Please
see the burner manufacturer’s literature for more information.
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.
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1.7 Safety Guidelines for Operating Gensets
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.
General
precautions
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, or tools within the genset
compartment. Items stored within the genset compartment are a fire hazard and
can restrict cooling air.
Before
operating the
genset
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.
DANGER
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.
Safety Information E 1100
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Running the
genset
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.
Refueling
safety
When adding fuel to the fuel tank:
Do not smoke.
Do not refuel a hot or running engine.
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.
Maintenance
safety
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, stand on a dry wooden platform 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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1.8 Service Safety
Service
training
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.
Precautions
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 operation. 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
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.
Replacing
parts and
labels
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 as the original components.
When replacement parts are required for this machine, use only Wacker
Neuson replacement parts or those parts equivalent to the original in all types of
specifications, such as physical dimensions, type, strength, and material.
Cleaning
When cleaning and servicing the machine:
Keep the machine clean and free of debris such as leaves, paper, cartons, etc.
Safety Information E 1100
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Keep the labels legible.
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)
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).
Maintenance
guidelines
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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Notes
Labels E 1100
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2 Labels
2.1 Label Locations
E 1100 Labels
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2.2 Safety Labels
1 WARNING!
Before operating this Ground Heater™, read
and fully understand the Operator’s Manual.
Failure to do so could result in serious injury
to the operator or bystander(s).
2 WARNING:
Read Operator’s Manual before operating
machine. Exhaust gas is deadly. Operate
machine only in well ventilated area. Do not
operate machine indoors.
3 WARNING:
Lug nuts factory torqued to 75 ft.lbs. Verify
lug nuts are properly torqued before trans-
porting. Failure to heed warning could result
in wheel loss which can cause injury or
death.
4 WARNING:
Attach chains or straps only to axles and
designated “tie-down” points. Never run
straps across any surface on this machine
which is painted red. Failure to heed above
warning could result in damage to personal
property or cause serious injury or death.
Attach Chains or Straps ONLY to Axles and
Designed "TIE DOWN" Points
168577
Never Run Straps Across Any Surface on this
Machine Which is Painted RED.
Failure to heed above warning could result in damage to
personal property or cause serious injury or death.
Labels E 1100
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5WARNING!
Hot fluids: gloves required.
Eye protection required.
Never loosen or remove hoses or operate
valves while pump is running.
Never loosen or remove hoses or operate
valves while heater is running.
Never loosen or remove hoses while fluid is
above 100 F (212 C).
Safety caps are screwed on to all hose bibbs
and valves which do not have factory
installed hoses attached. Never loosen or
remove a safety cap while fluid is above
100 F (212 C). Only remove a safety cap
in order to attach a hose. Do not operate
machine with safety caps missing.
Failure to heed these warnings could result
in serious burns and other personal injury to
operator or bystanders.
6DANGER!
Electric shock hazard.
Connect only to a grounded, GFI-protected
power source.
Position machine on the site such that nei-
ther the machine or the operator is standing
in water.
When operating hose rewind mechanism,
place foot pedal control on dry ground.
Failure to do so could result in serious injury
or death.
7DANGER:
Hazardous voltage. Do not operate without
this cover in place. Disconnect and lock out
power source before opening panel. Could
cause severe injury or death.
E 1100 Labels
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9 WARNING!
Jack should not be deployed for truck bed
transport. Properly support tongue with wood
block and retract jack before tightening
chains or straps. Jack is not designed to take
loads that ratcheting straps or load binded
chains can deliver. Use jack for raising or
lowering trailer tongue only. Failure to heed
these warnings could result in damage to
personal property or cause serious injury or
death.
Labels E 1100
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2.3 Informational Labels
Ref. Label Definition
10 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 num-
ber, item number, revision number, and serial
number of the unit.
11 Machine rating label: This label indicates rat-
ing information for the machine.
12 Burner setup.
This label indicates important setup informa-
tion for the burner.
13 HTF MSDS label.
This label is the Material Safety Data Sheet
for the HTF installed in the factory.
14 This heater operates at zero (atmospheric)
pressure and is not subject to regulations
applicable to pressurized boilers.
E 1100 Labels
ghi_si000402gb.fm 25
15 (on trailer)
Tire and loading information label:
This label indicates tire and loading informa-
tion for the trailer.
16 (on trailer)
VIN label. This label displays vehicle identifi-
cation numbers and other related informa-
tion.
Ref. Label Definition
Labels E 1100
26 ghi_si000402gb.fm
2.4 Procedural Labels
Ref. Label Definition
17 Do not reset.
Refer to Operator’s Manual.
18 Valve operation label
This label indicates the functions of the oper-
ational positions for valve #2.
19 Machine operating guide
This label is a guide to operating the
machine. Refer to the Operator’s Manual for
detailed instructions.
E 1100 Lifting and Transporting
wc_tx001809gb.fm 27
3 Lifting and Transporting
3.1 Lifting the Machine
Requirements
Properly-rated lifting equipment (crane or hoist)
Machine stopped
All doors and access covers closed and secured
Procedure
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.
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.
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.
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.
Lifting and Transporting E 1100
28 wc_tx001809gb.fm
3.2 Preparing the Machine for Transport on a Truck or Trailer
Requirements
Machine stopped.
Flatbed truck or trailer capable of supporting the machine’s weight.
Chains, hooks, or straps capable of supporting the machine’s weight.
Checklist
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 that the transport vehicle or trailer can support 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.
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.
E 1100 Lifting and Transporting
wc_tx001809gb.fm 29
3.3 Transporting the Machine on a Truck or Trailer
Requirements
Machine stopped
All doors and access covers closed and secured
Properly-rated ramps or docks
Properly-rated chains or straps
NOTICE: Do not run chains or straps across any painted surface. Failure to com-
ply may cause damage to your machine.
Procedure
Perform the procedure below to transport on a flat bed truck or trailer.
1. Move the machine onto the flat bed truck using properly-rated ramps or docks.
2. Install a support (a) under the trailer tongue.
NOTICE: Do not use the trailer jack to support the machine during transport.
3. Rotate the trailer jack (b) to the horizontal position.
4. If desired, rotate the trailer tongue (c) to a vertical position and secure it there.
5. Secure the machine to the bed with properly-rated chains or straps (d).
6. Install chocks (e) under both wheels.
Result
The machine is ready to be transported.
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.
Lifting and Transporting E 1100
30 wc_tx001809gb.fm
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 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 air pressure.
Trailer operation
Test the function of breakaway system. See topic Testing the Breakaway
System (Battery and Brakes).
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 operation of the trailer brakes by braking the towing vehicle 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.
E 1100 Lifting and Transporting
wc_tx001809gb.fm 31
3.5 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 Shutting Down and Packing Up
the Machine.
3. Adjust the amount of fuel in the machine to approximately 70% capacity 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.
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.
Lifting and Transporting E 1100
32 wc_tx001809gb.fm
3.6 Testing the Breakaway System (Electric Brakes)
Requirements
Voltmeter
Battery charger or backup battery (charged)
When
Test the breakaway system:
Before towing
Monthly if the machine is not in service
Procedure
Perform the following procedure to test the breakaway system.
NOTICE: Disconnect the trailer wiring plug from the tow vehicle before testing.
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.
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.
This procedure continues on the next page.
wc_gr008470
a
wc_gr008471
b
c
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.
E 1100 Lifting and Transporting
wc_tx001809gb.fm 33
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.
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.
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.
Result
The procedure to test the breakaway system is now complete.
wc_gr008472
d
VDC
1000
200
20
2
200m
F
V
A
V- COM
Operation E 1100
34 wc_tx001810gb.fm
4 Operation
4.1 External Components
wc_gr008412
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 cap 9 Lifting bail (option)
5 Performance monitoring light - ---
E 1100 Operation
wc_tx001810gb.fm 35
4.2 Internal Components
1 This heater operates at zero (atmospheric) pressure and is not subject to regulations applica-
ble to pressurized “boilers”.
Ref. Description Ref. Description
a Duplex receptacle h Hose reel and hose
b Pressure and temperature gauges i Hose quick-connect
c Flow gauge j Hose reel brake T-handle
d Rewind system foot control pedal k Fuel filter
e Temperature controller l Low-level shut-down device
f Control panel m Burner
g Heat Transfer Fluid (HTF) reser-
voir gauge
n Hydronic heater
1
Operation E 1100
36 wc_tx001810gb.fm
4.3 Control Panel
Ref Description Function
a Ground Fault Circuit Interrupt Provides protection for the operator.
b Circuit breaker Controls power to the machine.
c Low level indicator Indicates low heat transfer fluid level.
d Burner fault indicator Indicates burner faults.
e HTF fill ON/OFF switch Overrides the Low Level Fault mode to
enable HTF filling procedures.
f Pump ON/OFF switch Controls power to the pump.
g Hose rewind ON/OFF switch Controls power to the hose rewind motor.
h Burner ON/OFF switch Controls power to the burner.
i Temperature controller
Allows the user to control the HTF target
application temperature.
Shows the actual temperature of the HTF.
j Hour meter Meters usage of the machine.
E 1100 Operation
wc_tx001810gb.fm 37
4.4 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.
Or, when at the job site before
daily operation.
4.5
2. Check fuel level. 4.6 / 4.7
3. Position the machine. At the job site. 4.8
4. Connect power. 4.9
5. Perform pre-starting checks. 4.10
6. Power up the machine. 4.11
5. Run the machine.
a. Preheat the HTF (if necessary). 4.12
b. Initiate HTF flow. 4.13
c. Unwind and position the hoses. 4.14 / 4.15
d. Monitor the operating parameters. 4.16
e. Adjust the burner (if necessary). Burner
Setup
6. Rewind the hoses 4.17
7. Shut down and pack up the machine. 4.18
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Wacker Neuson E1100 Manuel utilisateur

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Manuel utilisateur

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