S 3000products.wackerneuson.com/manuals/Repair/0178388enRep.pdf · S 3000 REPAIR MANUAL 0178388en 002 0209 0178388 EN. S 3000 Repair Foreword ... Use the separate Parts Book supplied

Hydronic Surface Heater

S 3000

REPAIR MANUAL

0178388en 002

0209

0 1 7 8 3 8 8 E N

S 3000 Repair Foreword
ForewordMachines covered by this manual
Machine documentation

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. If you are missing any of these documents, please contact Wacker Neuson Cor-poration 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 repair 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 man-ual. Wacker Neuson Corporation 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 Corporation reserves the right to change any portion of this information without notice.

Copyright notice

All rights, especially copying and distribution rights, are reserved.Copyright 2008 by Wacker Neuson Corporation.This publication may be reproduced through photocopying by the original purchaser of the machine. Any other type of reproduction is prohibited without express written permission from Wacker Neuson Corporation.Any type of reproduction or distribution not authorized by Wacker Neuson Cor-poration represents an infringement of valid copyrights, and violators will be prosecuted.

Trademarks All trademarks referenced in this manual are the property of their respective own-ers.

Machine Item NumberS 3000 0620182S 3000 0620218

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Foreword S 3000 Repair

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S 3000 Table of Contents
1 Safety Information 9
1.1 Signal Words Found in this Manual ...................................................... 91.2 Safety Guidelines for Operating the Machine ..................................... 101.3 Safety Guidelines for Lifting the Machine ........................................... 111.4 Safety Guidelines While Using Combustion Burners ......................... 121.5 Safety Guidelines while Using Internal Combustion Engines ............. 121.6 Safety Guidelines for Maintaining the Machine .................................. 13

2 Controls and Components 14

2.1 External Components ......................................................................... 142.2 Internal Components .......................................................................... 152.3 Control Panel Detail ........................................................................... 17

3 Troubleshooting Basics 18

3.1 Where to Start .................................................................................... 18

4 Power Components 19

4.1 Checking the Power Supplies ............................................................ 204.2 Checking a Circuit Breaker ................................................................. 214.3 Checking a GFCI ................................................................................ 23

5 Heating System 25

5.1 Burner Controller Periods and Modes ................................................ 255.2 Troubleshooting the Heating System ................................................. 295.3 Checking the Burner Switch ............................................................... 305.4 Checking the Low-Level Shut-Down Device ...................................... 325.5 Checking Relay K2 ............................................................................. 345.6 Diagnosing the Heating System ......................................................... 365.7 Checking the Temperature Controller ................................................ 385.8 Checking the Burner Controller .......................................................... 405.9 Checking the Snap Disc (Thermal Limit) ............................................ 43

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Table of Contents S 3000
5.10 Checking the Burner Fan Motor ..........................................................455.11 Checking the Cad Cell .........................................................................475.12 Checking the Oil Valve ........................................................................495.13 Checking the Fuel Filter ......................................................................515.14 Checking the Ignition Transformer ......................................................525.15 Checking the Thermocouple ...............................................................54
6 Circulation System 56

6.1 Diagnosing the Circulation System .....................................................566.2 Troubleshooting the Circulation System ..............................................576.3 Checking the Pump Switches ..............................................................586.4 Checking the Low-Level Shut-Down Device .......................................606.5 Checking Relay K1 ..............................................................................626.6 Checking the Pump Motors .................................................................64

7 Rewind System 66

7.1 Troubleshooting the Rewind System ...................................................667.2 Checking Fuse 1 and Fuse 2 ..............................................................677.3 Checking the Rectifier .........................................................................687.4 Checking the Rewind Transformer ......................................................697.5 Checking the Foot Switch ....................................................................717.6 Checking the Rewind Switch ...............................................................737.7 Checking the Rewind Clutch (Solenoid) ..............................................757.8 Checking the Rewind Motor ................................................................767.9 Checking the Rewind System Mechanical Components .....................78

8 Miscellaneous Components 79

8.1 Checking an Indicator Light .................................................................798.2 Checking the Fuel Prewarmer .............................................................80

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S 3000 Table of Contents
9 Burner Setup 83
9.1 Setting/Checking the Electrodes ........................................................ 899.2 Replacing the Burner Nozzle .............................................................. 919.3 Setting the “Z” Distance (“F” head) ..................................................... 949.4 Adjusting the Air Settings ................................................................... 969.5 Setting the Fuel Pressure ................................................................... 97

10 Disassembly and Assembly 98

10.1 Tools Required for Disassembly/Assembly Procedures ..................... 9810.2 Information Regarding Replacement Parts ........................................ 9810.3 Information Regarding Reference Numbers ....................................... 9810.4 Removing the Burner ......................................................................... 9910.5 Installing the Burner ......................................................................... 10010.6 Replacing the Fuel Pump ................................................................. 10110.7 Replacing the Burner Fan Motor ...................................................... 10410.8 Replacing an HTF Pump .................................................................. 10610.9 Changing a Turbulator/Cleaning a Turbulator Tube ......................... 10910.10 Repairing a Hose .............................................................................. 11010.11 Changing/Cleaning the HTF Filter .................................................... 11210.12 Changing Low Level Probe .............................................................. 11410.13 Replacing the Thermocouple ........................................................... 116

11 Schematics 117

11.1 S 3000 Composite Schematic .......................................................... 11711.2 S 3000 Composite Components ...................................................... 11811.3 Heating System Circuit ..................................................................... 12111.4 Circulation System Circuit ................................................................ 12211.5 Rewind System Circuit ..................................................................... 123

12 Technical Data 125

12.1 S 3000 .............................................................................................. 12512.2 Dimensions ....................................................................................... 126

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Table of Contents S 3000
13 Appendix 127
13.1 Omron Temperature Controller Programming ...................................12713.2 Fuji Temperature Controller Hysteresis (differential) Adjusting .........12813.3 Fuji Temperature Controller Low Temperature Limit Adjusting .........12913.4 Fuji Temperature Controller High Temperature Limit Adjusting ........13013.5 Threadlockers and Sealants ..............................................................13113.6 Torque Values ...................................................................................133

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S 3000 Safety Information
1 Safety Information
1.1 Signal Words Found in this Manual

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

Note: Contains additional information important to a procedure.

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

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

Obey all safety messages that follow this symbol to avoid injury or death.

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

Obey all safety messages that follow this symbol to avoid possible injury or death.

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

Obey all safety messages that follow this symbol to avoid possible minor or moderate injury.

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Safety Information S 3000
1.2 Safety Guidelines for Operating the MachineOperator 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 Corporation 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.

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.

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.Wear protective clothing appropriate to the job site when operating the machine.Wear safety glasses.Wear gloves when handling the heat transfer hoses.

When operating the machine:Never 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.

Work space When operating the machine:Position the machine on a firm, noncombustible, level surface, and chock wheels.Position the machine on the job site so that neither it or the operator are stand-ing in water.

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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.

1.3 Safety Guidelines for Lifting the MachineLifting/transporting the machine

When lifting/transporting the machine:Make sure all lifting devices are attached securely and have enough weight-bearing capacity to lift or hold the machine safely. 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.Only use suitable transport vehicles with sufficient load-carrying capacity.

When lifting the machine:Never walk or stand under a suspended machine.Never climb, sit, or stand on the machine while it is being lifted or transported.Do not operate the machine when it is being lifted or towed.


Safety Information S 3000
1.4 Safety Guidelines While Using 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:

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.

1.5 Safety Guidelines while Using Internal Combustion EnginesRunning the engine

When running the engine:Keep the area around exhaust pipe free of flammable materials.Check the fuel lines and the fuel tank for leaks and cracks before starting the engine. Do not run the machine if fuel leaks are present or the fuel lines are loose.

When running the engine:Engine exhaust CAN KILL YOU IN MINUTES. Engine exhaust contains carbon monoxide. This is a poison you cannot see or smell. Never run the machine indoors or in an enclosed area such as a deep trench unless adequate ventila-tion, through such items as exhaust fans or hoses, is provided. Do not smoke while operating the machine.Do not run the engine near open flames.Do not touch the engine or muffler while the engine is running or immediately after it has been turned off.Do not operate a machine when its fuel cap is loose or missing.

DANGERExhaust gas from the burner contains carbon monoxide, a deadly poison. Exposure to carbon monoxide can kill you in minutes.

Never run the machine indoors or in an enclosed area unless the machine is vented properly.


1.6 Safety Guidelines for Maintaining the MachineTraining Only trained personnel should troubleshoot or repair electrical problems
occurring with the machine.

Cleaning When cleaning and servicing the machine:Keep the area around the burner free of debris such as leaves, paper, cartons, etc.Keep the machine clean and 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 parts. Fumes from fuels and solvents can become explosive!

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.Re-install the safety devices and guards after repairs and maintenance.Keep all electrical cords away from heat, oil, vibrating surfaces, and sharp edges.

Replacing parts and labels

When maintaining the machine:Replace worn or damaged components.Use only spare parts recommended by Wacker Neuson Corporation.Replace all missing and hard-to-read labels.Replace or repair electrical components with components that are identical in rating and performance as the original component.

When maintaining the machine:Do not attempt tire repairs.

Accessories, safety devices and modifications

When using the machine:Use only accessories/attachments that are recommended by Wacker Neuson Corporation.

When using the machine:Never operate the machine if any safety devices or guards are missing or inoperative.Do not defeat safety devices. Do not modify the machine without the express written approval of Wacker Neuson Corporation.


Controls and Components S 3000
2 Controls and Components
2.1 External Components

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Ref. Description Ref. Description1 Hitch (ball or pintel) 5 Fender2 Tie down 6 Onan genset (option)3 Fuel tank 7 Jack stand4 Fuel cap 8 Lifting bail

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S 3000 Controls and Components
2.2 Internal Components
Ref. Description Ref. Descriptiona Genset 12V battery g Fuel sight gaugeb Hydronic heater h Fuel sight gauge valvec Heat Transfer Fluid (HTF) pmp i Burnerd Expansion tank sight gauge j Low-level shut-down devicee Fuel filter k Thermocouplef Fuel return line n/a n/a


Controls and Components S 3000

Ref. Description Ref. Descriptiona Control panel e Foot pedalb Return plumbing f Hose reelc Supply plumbing g Main power connectionsd Hose reel brake h Expansion tank


S 3000 Controls and Components
2.3 Control Panel Detail

Troubleshooting Basics S 3000


3 Troubleshooting Basics

3.1 Where to StartThe chart below lists the four basic problems the machine may experience. Refer to the chart to determine which chapter to see for each basic problem.

If ThenThe machine does nothing when turned on, see Chapter 4 Power Components.The machine does not heat the HTF, see Chapter 5 Heating System.The machine does not circulate the HTF, see Chapter 6 Circulation System. The machine does not rewind the hose, see Chapter 7 Rewind System.

S 3000 Power Components
4 Power ComponentsComponents For any system of the machine to function, the following three power components
must function properly:Power supply (supplies)Main circuit breaker(s)GFCI(s)

Best practice The best practice when troubleshooting the power components is to:

1. Isolate and check each power component individually. 2. When a malfunctioning component is found, repair or replace it.

This chapter of the manual provides procedures to check the power components.

Testing sequence

Check the function of the power components in the sequence below.

1. Power supplySee Section 4.1 Checking the Power Supplies.

2. Main circuit breakerSee Section 4.2 Checking a Circuit Breaker.

3. GFCISee Section 4.3 Checking a GFCI.


Power Components S 3000
4.1 Checking the Power SuppliesPrerequisites Two sources of 120 VAC
Two 10-gauge, 3-wire extension cords max. 100 feet not applicable for machines with generators

Procedure Follow the procedure below to check the power supplies.

1. Check the connection of each extension cord. One should be connected to “Main Power 1” and the other to “Main Power 2”.

2. Place circuit breaker 1 in the ON position.3. Place circuit breaker 2 in the ON position.

4. Open the control panel.

5. Measure the voltage between L1 and N1.Is 108–132 VAC measured?

6. Measure the voltage between L2 and N2.Is 108–132 VAC measured?

The power supplies have now been checked. Continue with Section 4.2 Checking a Circuit Breaker.

WARNINGElectric shock hazard. High voltage exists inside the control panel. High voltage can cause severe injury or death.

Use extreme care when working inside the control panel.

Yes ____ No ____Continue. The supply source is inadequate or non-existent. Check the

power source.

Yes ____ No ____The power supplies

are OK.The power source is inadequate or non-existent. Check the power

source (generator or wall outlet).

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4.2 Checking a Circuit BreakerPrerequisites Power supplies check OK
Multimeter

Background The procedures to check either circuit breaker are similar. Use terminal N1 of the terminal strip for neutral when checking circuit breaker 1. Use terminal N2 of the terminal strip for neutral when checking circuit breaker 2.

Procedure Follow the procedure below to check a circuit breaker.

1. Verify that each power source is plugged in.

2. Open the control panel.3. Measure the voltage between the incoming side of the circuit breaker and

neutral.

Is 108–132 VAC measured?

4. With the circuit breaker in the OFF position, measure the voltage between the outgoing side of the circuit breaker and neutral.

Is any voltage measured?

This procedure continues on the next page.



Yes ____ No ____Continue. The wiring to the circuit breaker is faulty. Disconnect the main

power supplies and repair the wiring.

Yes ____ No ____The circuit breaker has failed. Disconnect the main power

sources and replace the circuit breaker.Continue.


Continued from the previous page.
5. Place the circuit breaker in the ON position.6. With the circuit breaker in the ON position, measure the voltage between the

outgoing side of the circuit breaker and neutral.

The circuit breaker has now been checked. Continue with Section 4.3 Checking a GFCI.



Yes ____ No ____The circuit breaker is OK. The circuit breaker has failed. Disconnect

the main power supplies and replace the circuit breaker.


4.3 Checking a GFCIPrerequisites Power supplies check OK
Circuit breakers check OK

Background The procedures to check either GFCI are similar. Use terminal N1 of the terminal strip for neutral when checking GFCI 1. Use terminal N2 of the terminal strip for neutral when checking GFCI 2.

Procedure Follow the procedure below to check either GFCI.

1. Verify that each power supply is plugged in.

2. Open the control panel.3. Place the circuit breaker of the GFCI to be tested in the ON position.4. Measure the voltage between the black wire on the incoming side (b) of the

GFCI and neutral.


5. Measure the voltage between the white and the black wires on the incoming side of the GFCI.





Yes ____ No ____Continue. The black wire to the GFCI is faulty. Disconnect the main power

supplies and repair the wiring.

Yes ____ No ____Continue. The white wire to the GFCI is faulty. Disconnect the main power



6. Push the OFF/TEST button on the face of the GFCI.

Does the test light (a) of the GFCI illuminate?

7. Measure the voltage between the white and the black wires on the outgoing side of the GFCI.


8. Press the ON/RESET button. With the ON/RESET button pushed in, measure the voltage between the white and the black wires on the outgoing side of the GFCI.


The GFCI has now been checked. Power is available to the components of the machine. If the machine still does not function, refer to Section 3.1 to determine which system and corresponding components should be checked.

Yes ____ No ____Continue. The GFCI has failed.

Disconnect the main power supplies and replace the GFCI.

Yes ____ No ____Continue. The GFCI has failed.


Yes ____ No ____The GFCI is OK. The GFCI has failed.



S 3000 Heating System
5 Heating System
5.1 Burner Controller Periods and Modes

Periods The burner controller has several periods it sequences through during normal operation. These periods are described below..

Period Action or FunctionPower up As soon as power is supplied to the burner controller, it conducts an

internal safety check. If all internal conditions are OK, the burner controller enters the idle mode and will remain there until there is a call for heat or power is disconnected.

Safety(5 seconds)

When the setpoint of the temperature controller is set at a temperature higher than that of heat transfer fluid, the output contacts of the temper-ature controller close completing a circuit between terminal “T” and “3T” of the burner controller. This is the call for heat.

The burner controller initiates the safety period.

If flame or light is detected, the burner controller remains in the idle mode and no other functions take place.If flame or light is not detected after 5 seconds:

Power is sent to the burner motor/fuel pump. Fuel is pumped from the supply tank and returned to the supply tank through the return/bypass port of the fuel pump. This process purges air from the fuel lines.Power is sent to the electrodes and any residual fuel is burned off.Fresh air fills the combustion chamber. The valve-on-delay period starts.

Valve-on-delay

The valve-on-delay period lasts 15 seconds. It is enabled (turned on or off) with DIP switch 3. When enabled:

Power is sent to the burner motor/fuel pump.Power is sent to the electrodes.The fuel shut-off valve is energized (opens) and fuel flows to the nozzle after the valve-on-delay times out.


Heating System S 3000

Non-fault modes

The burner non-fault modes are described below.

Trial-for-ignition

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

The fuel shut-off valve is opened (energized).Pressurized fuel atomizes at the burner nozzle.The atomized fuel is vaporized and ignited by the electrodes.The burner fires and the flame is monitored by the cad cell.

If flame is not detected: The burner controller enters lockout mode.Power is disconnected from the fuel shut-off valve, electrodes, and the burner motor.The indicator light flashes.

Carry-over The ignition carry-over period starts as soon as the flame is established. During this cycle:

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 30 seconds after flame is sensed.

Once the carry-over period has expired:The ignition transformer is shut off.The burner controller enters the run mode.

If the flame is lost: If the lockout time has not expired, the burner controller returns to trial-for-ignition period.If the lockout time has expired, the burner controller enters the recycle mode.

Burner-motor-off delay

The burner-motor-off-delay period starts immediately after the setpoint is reached, i.e., the call for heat has been satisfied. The time of this period is set by the DIP switches (DIP switches 1 and 2 in the down position; 3 in the up position). During this period:

The fuel shut-off valve is closed (de-energized).The burner motor runs until the burner-motor-off delay expires, then the burner motor turns off.The burner controller returns to the idle mode.

Period Action or Function

Mode Functional descriptionIdle The burner controller will enter the idle mode if:

At power up, the internal conditions are correct and the cad cell senses no light.The cad cell senses light during the safety period.The call for heat has been satisfied.

During this mode:The burner controller powers no outputs.




Startup The burner controller will enter the startup mode as soon as there is a call for heat. This mode consists of the following periods:

SafetyValve-on-delayTrial-for-ignitionCarry-over

Run The run mode starts and continues once the ignition carry-over period has elapsed. During this mode:

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

Once the setpoint is reached (call for heat satisfied):The output contacts of the temperature control open, interrupting the circuit between terminal “T” and “3T”.The fuel shut-off valve is closed (de-energized).The burner motor runs for the selected burner-motor-off delay time (period), then turns off.The burner controller returns to the idle mode.

If the flame is lost during the run mode:The burner controller enters the recycle mode.

Recycle The burner will enter the recycle mode when the burner stops firing due to loss of flame. During the recycle mode:

The diagnostic light on the burner controller will flash in two-second intervals.The burner will attempt to automatically restart.

Flame must be detected during each restart attempt. If no flame is detected, the burner controller goes into burner fault lockout mode.The burner controller will wait 60-seconds between restart attempts.If after three restart attempts in which the call for heat is not satisfied, the burner controller will go into burner fault lockout mode.If the call for heat is satisfied, the recycle counter resets.

Mode Functional description


Fault modes The burner controller fault modes are described below.

Lockout The burner will enter the lockout mode after three unsuccessful attempts to re-light the flame.During the lockout mode:

The burner will not fire.The diagnostic light on the burner controller will flash in half-second intervals.The burner fault light on the control panel will illuminate.

To clear the 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 controller will enter the restricted mode.

Restrictedlockout

The burner will enter the restricted mode after three unsuccessful attempts to manually reset the lockout fault.During the lockout mode:

The burner will not fire.The diagnostic light on the burner controller will flash in half-second intervals.The burner fault light on the control panel will illuminate.

To clear the restricted lockout fault so a restart can be attempted, press and hold (approximately 30–45 seconds) the reset button until the diagnostic light flashes once. Note: The burner will return to the lockoutmode with each unsuccessful burner restart until a successful heating cycle has occurred.


5.2 Troubleshooting the Heating System
Best practice The best practice when troubleshooting the heating system is to:

1. Isolate and check each component of the heating system individually. 2. When a malfunctioning component is found, repair or replace it. 3. After replacing a malfunctioning component, retry system operation.

This chapter of the manual provides procedures to check the components of the heating system.

Fundamental components

For the heating system to function, the following three fundamental components must function properly.

Burner switchLow-level shut-down deviceRelay K2

Testing sequence

Before performing any troubleshooting procedures of the heating system, check the function of the fundamental components in the sequence below.

Note: If power (108–132 VAC) exists at the burner switch, it means the other fun-damental components are functioning properly. In such a case, there is no need to test them.

If the heating system still does not function after verifying the fundamental components, see Section 5.6 Diagnosing the Heating System.

1. Burner switchSee Section 5.3 Checking the Burner Switch.

2. Low-level shut-down deviceSee Section 5.4 Checking the Low-Level Shut-Down Device.

3. Relay K2See Section 5.5 Checking Relay K2.


5.3 Checking the Burner SwitchPrerequisites Power components check OK
Power connected to the machine

Procedure Follow the procedure below to check the burner switch.

Note: If power (108–132 VAC) exists at the burner switch, it means the other fun-damental components are functioning properly. In such a case, there is no need to test them.

1. Open the control panel.2. Place circuit breaker 1 in the ON position.3. Place the burner switch (a) in the OFF position.

4. Measure the voltage between terminal/wire 18 on the incoming side of the burner switch and N1 of the main terminal strip.





If ThenYes, continue with step 5.No, one of the fundamental components has failed.

Check:the low-level shut-down device. See Section 5.4 Checking the Low-Level Shut-Down Device.relay K2. See Section 5.5 Checking Relay K2.


5. With the burner switch still in the OFF position, measure the voltage between terminal/wire 10 on the outgoing side of the burner switch and N1 of the main terminal strip.


6. Place the burner switch in the ON position.7. Measure the voltage between terminal/wire 10 on the outgoing side of the

burner switch and N1 of the main terminal strip.Is 108–132 VAC measured?

The burner switch has now been checked. If the heating system still does not function, continue with Section 5.4 Checking the Low-Level Shut-Down Device.

Yes ____ No ____The burner switch has failed. Disconnect the power supplies

and replace the burner switch.Continue.

Yes ____ No ____The burner switch and all fundamental

components are OK.The burner switch has failed. Disconnect

the power supplies and replace the burner switch.


5.4 Checking the Low-Level Shut-Down DevicePrerequisites All power components check OK
Multimeter

Procedure Follow the procedure below to check the low-level shut-down device.

1. Check the level of the HTF on the sight gauge. Add HTF as necessary.

2. Turn off circuit breaker 1 and circuit breaker 2.3. Open the side panel and locate the low-level shut-down device (a).

4. Remove the cover from the low-level shut-down device.5. Remove the wing nut and the probe wire from the probe (b).

6. Measure the resistance between the end of the probe and ground (bare metal location on the heater unit).

Is any resistance measured?


WARNINGElectric shock hazard. High voltage exists inside the low-level shut-down device. High voltage can cause severe injury or death.

Use extreme care when working inside the low-level shut-down device.

Yes ____ No ____Reconnect the probe and continue. The probe has failed; replace it.


7. Turn on circuit breaker 1 and circuit breaker 2.

8. Measure the voltage between wire/terminal black 17 and N2 of the main terminal strip. Also measure between wire/terminal orange 1 and N1 of the main terminal strip.

Is 108–132 VAC measured in each case?

9. Measure the voltage between the black wire 17 and the white wire/terminal of the low-level shut-down device.


10.Measure the voltage between red wire 5 and N1 of the terminal strip.Is 108–132 VAC measured?

The low-level shut-down device has now been checked. If the heating system still does not function, see Section 5.5 Checking Relay K2.



Yes ____ No ____Continue. The wiring (orange 1 or black 17) is faulty.

Disconnect the power supplies and repair the wiring.

Yes ____ No ____Continue. The white wire is faulty.


Yes ____ No ____The low-level shut-down device is OK.

The low-level shut-down device has failed. Disconnect the power supplies and replace it.


5.5 Checking Relay K2Prerequisites All power components check OK
Multimeter

Procedure Follow the procedure below to check relay K2.

1. Place circuit breaker 1 and circuit breaker 2 in the OFF position.

2. Open the control panel.3. Locate relay K2.

4. Label, then disconnect the wires from relay K2.5. Measure the resistance across the coil of the relay (terminals 0 and 1).Is 825–1025 ohms measured?

6. Measure the resistance (check continuity) across normally closed contacts (terminals 3 and 4).

Is approximately 0.1 ohms measured?

7. Measure the resistance across normally open contacts (terminals 2 and 4).Is any resistance measured?




Yes ____ No ____Continue. Relay K2 has failed; replace it.


Yes ____ No ____Relay K2 has failed; replace it. Continue.


8. Reconnect the wiring to relay K2.

9. Place circuit breaker 1 and circuit breaker 2 in the ON position.10.Measure the voltage between the incoming side (wire 18) of the burner switch

(a) and N1 of the main terminal strip.


11.Measure the voltage between the incoming side (wire 26) of the low-level fault light and N1 of the main terminal strip.


Relay K2 has now been checked. The fundamental components of the heating system are OK. If the heating system still does not function, see Section 5.6 Diagnosing the Heating System.



Yes ____ No ____Continue. Relay K2 has failed. Disconnect the power

supplies and replace relay K2.

Yes ____ No ____Relay K2 has failed. Disconnect the power

supplies and replace relay K2.Relay K2 is OK.


5.6 Diagnosing the Heating SystemPrerequisites All power components check OK
All fundamental components check OK

Procedure Follow the procedure below to determine which component(s) of the heating system to check.

1. Place circuit breaker 1 and circuit breaker 2 in the ON position.2. Place the burner switch in the ON position.3. Set the temperature controller to 180°F.

Does the display of the temperature controller and LED C1 (a) illuminate?

4. Observe the burner fault light on the control panel.Does the BURNER FAULT light illuminate?


Yes ____ No ____Continue. See Section 5.7 Checking the Temperature Controller.

Yes ____ No ____Continue. There is a problem with one of the two components below. Verify

the wiring to, and function of, each component. See the following sections in order:

Section 5.8 Checking the Burner ControllerSection 8.1 Checking an Indicator Light


5. Locate the primary control (a).

6. Push the red reset button (b) on the primary control for 45 seconds and release.Does the burner attempt to start?

7. If the burner attempted to start, follow the guide below.

The procedure is now complete.

Yes ____ No ____Continue. The problem is one of the three components below. Verify the

wiring to, and function of, each component. See the following sections in order:

Section 5.8 Checking the Burner ControllerSection 5.9 Checking the Snap DiscSection 5.10 Checking the Burner Fan Motor

If ThenIgnition occurs and the burner stays lit, use machine as normal.Ignition occurs then stops after approximately 20 seconds of blower run time,

the problem is the cad cell.See Section 5.11 Checking the Cad Cell.

Ignition does not occur and the blower stops after approximately 20 seconds of blower run time,

the problem is one of the four components below. Verify the wiring to, and function of, each component. See the following sections in order: Section 5.12 Checking the Oil ValveSection 5.13 Checking the Fuel FilterSection 9.2 Replacing the Burner NozzleSection 5.14 Checking the Ignition TransformerSection 9.1 Setting/Checking the Electrodes


5.7 Checking the Temperature Controller
Prerequisites Power components check OKFundamental components check OK

Procedure Follow the procedure below to check the temperature controller.

1. Place circuit breaker 1 and circuit breaker 2 in the ON position.2. Observe the temperature controller.Does the temperature controller read “UUUU” or “5ERR”?

3. Open the control panel and locate the back of the temperature controller.

4. Place circuit breaker 1 and circuit breaker 2 in the OFF position.5. Check continuity between the wire connected to terminal 6 and neutral (N1 on

the main terminal strip). There must be continuity (0.1 Ohms). Repair or replace the wire as needed.

6. Place circuit breaker 1 and circuit breaker 2 in the ON position.7. Place the burner switch in the ON position.8. Measure the voltage between wire #1 connected to temperature controller

(terminal 5) and neutral (N1 on the main terminal strip).Is 108–132 VAC measured?


Yes ____ No ____Check the connection of the thermocouple wires (terminals 17 & 18). Make sure the blue wire is connected to terminal 17; red to terminal 18. If the controller still reads “UUUU” or “5ERR” see Section 5.15 Checking the Thermocouple.

Continue.



Yes ____ No ____Continue. Disconnect the power sources and repair wire #1.


9. Adjust the temperature controller to 180°F by pressing the UP arrow.10.Check the C1 LED (a) on the front face of the temperature controller.

Does the LED and the readout display illuminate?

11.Disconnect the wires from terminals 14 and 15. 12.With the temperature controller still set at 180°F, measure the resistance

(continuity) across the terminals.Is 0.1 Ohms measured?

The temperature controller has now been checked. If the heating system still does not function, see Section 5.8 Checking the Burner Controller.

Yes ____ No ____Continue. The temperature controller has failed. Disconnect the power

supplies and replace the temperature controller.

Yes ____ No ____The temperature controller should be OK. If you suspect a problem with the programming of the temperature controller, see Appendix.

The temperature controller has failed. Disconnect the power supplies and replace the temperature controller.


5.8 Checking the Burner Controller

Procedure Follow the procedure below to check power to the primary control.

1. Place circuit breaker 1 in the ON position.2. Set the temperature controller to 50°F.3. Place the burner switch in the ON position.4. Measure the voltage between terminal T and terminal 3T of the primary control.


5. Place circuit breaker 1 in the OFF position.

6. Remove the primary control by loosening screws (c).


Yes ____ No ____Continue. The wiring between the temperature controller and the primary

control may have failed. Check the wiring.

CAD CELL

L1

L2

L2

L2

L2

INTRPT/IGNITER

2

BURNER/MOTOR

LIMIT

VALVE


7. Check the connections and the continuity of white wire 2 that runs between an L2 terminal of the primary control and the terminal strip.

Does the wire have continuity?

8. Place circuit breaker 1and circuit breaker 2 in the ON position.9. Place the burner switch in the ON position.10.Measure the voltage between wire 10 (at the LIMIT terminal) and any L2

terminal of the primary control.

Is 108 –132 VAC measured?

11.Measure the voltage between wire 1 (at the L1 terminal) and any L2 terminal of the primary control.



Yes ____ No ____Continue. Wire 2 between the L2 terminal and the terminal strip has failed;

replace it.

WARNINGElectric shock hazard. High voltage exists inside the primary control. High voltage can cause severe injury or death.

Use extreme care when working inside the primary control.

Yes ____ No ____Continue. Wire 10 between the LIMIT terminal and the burner switch has

failed. Disconnect the power supplies and repair wire 10.

Yes ____ No ____Continue. Wire 1 between the L1 terminal and the terminal strip has failed.

Disconnect the power supplies and repair wire 1.


12.Turn OFF and then back ON the burner switch. After the burner purge cycle, measure the voltage between the INTRPT/IGNITER terminal and any L2 terminal.


13.Continue with the burner switch in the ON position14.Measure the voltage between the BURNER/MOTOR terminal and any L2

terminal.Is 108 –132 VAC measured?

15.Measure the voltage between the VALVE terminal and any L2 terminal.


The primary control has now been checked. If the heating system still does not function, see Section 5.9 Checking the Snap Disc.

Yes ____ No ____Continue. The primary control has failed. Disconnect the power supplies and

replace the primary control.

Yes ____ No ____Continue. The primary control has failed. Disconnect the power supplies and

replace the primary control.

Yes ____ No ____The primary control

is OK.The primary control has failed. Disconnect the power supplies and replace the primary control.


5.9 Checking the Snap Disc (Thermal Limit)
Prerequisites Machine coolMultimeter

Procedure Follow the procedure below to check the snap disc.

1. Place circuit breaker 1 and circuit breaker 2 in the OFF position.2. Locate the snap disc above the furnace chamber. It is located in a brass

housing (a).

3. Reset the snap disc by pushing in the reset button (b).4. Remove the face plate of the brass housing.5. Remove the two wires that lead to the snap disc.6. Measure the resistance across the terminals of the snap disc.Is approximately 0.1 ohms measured?


WARNINGBurn hazard. The furnace chamber is hot when the machine is operating. If touched, it may cause severe burns.

Allow the furnace chamber to cool before performing this test.

Yes ____ No ____Continue. The snap disc has failed; replace it.


7. Re-attach the wires to the snap disc.8. Remove the primary control by loosening the screws (d).

9. Among the wires of the primary control junction box, locate the wire that runs from the primary control to the snap disc (e). Also locate the wire that runs from the snap disc to the burner motor. Disconnect each wire.

10.Measure the resistance between the two wires that run to the snap disc.Is approximately 0.1 ohms measured?

The procedure to check the snap disc is now complete. If the heating system still does not function, see Section 5.10 Checking the Burner Fan Motor.

Yes ____ No ____The snap disc and its wiring are OK. The wiring to the snap disc has failed;

replace it.


5.10 Checking the Burner Fan Motor
Prerequisites Power components check OKMultimeter

Procedure Follow the procedure below to check the burner fan motor.


2. Locate and remove the orange wire and the white wire (that power the burner fan motor) from the primary control.

3. Measure the resistance between the orange wire and white wire.Is 4.5–5.5 ohms measured?

4. Measure the resistance between one of the wires and ground.Is infinity ohms (OL) measured?

5. Reconnect the orange wire.


WARNINGElectric shock hazard. High voltage exists inside the primary control. High voltage can cause severe injury or death.

Start this test with circuit breaker 1 and circuit breaker 2 in the OFF position.

Yes ____ No ____Continue. The burner fan motor has failed; replace it.

Yes ____ No ____Continue. The burner fan motor has failed; replace it.

CAD CELL

L1

L2

L2

L2

L2

INTRPT/IGNITER

2

BURNER/MOTOR

LIMIT

VALVE


6. Place circuit breaker 1 and circuit breaker 2 in the ON position.

7. Place the burner switch in the ON position.8. Measure the voltage between the white wire and N1 of the main terminal strip.Is 108–132 VAC measured?

The burner fan motor has now been checked.

WARNINGElectric shock hazard. High voltage exists on the burner fan motor when the burner switch is in the ON position. High voltage can cause severe injury or death.

Use extreme care when working on the burner fan motor.

Yes ____ No ____The burner fan motor

is OK.The burner fan motor has failed; disconnect the power supplies

and replace the burner fan motor.


5.11 Checking the Cad Cell
Prerequisites Power disconnected from the machineMultimeter

Procedure Follow the procedure below to check the cad cell.


2. Loosen tabs (b) and hinge back the igniter plate cover.3. Disconnect the yellow wires (d) from the bottom of the primary control.

4. Measure the resistance of the cad cell (e) by measuring across the yellow wires. Be sure the cad cell is exposed to light.

Is 50–400 ohms measured?


Yes ____ No ____Continue. The cad cell is dirty or defective. First, clean the glass eye, then

re-measure. If the reading remains out of the range listed above, replace the cad cell.


5. Deprive the cad cell of light (cover the cad cell) and measure the resistance again.

Is 20,000–50,000 ohms measured?

The procedure to check the cad cell is now complete.

Yes ____ No ____The cad cell is OK. The cad cell is dirty or defective. First, clean the glass eye, then

re-measure. If the reading remains out of the range listed above, replace the cad cell.


5.12 Checking the Oil ValvePrerequisites Power components check OK
Fundamental components check OK

Procedure Follow the procedure below to check the oil valve.


2. Place circuit breaker 1 and circuit breaker 2 in the ON position.3. Position all dip switches (a) in the “down” or “disabled” position.

4. Remove the oil valve electrical plug (b).

5. Place the burner switch in the ON position.


CAD CELL

L1

L2

L2

L2

L2

INTRPT/IGNITER

2

BURNER/MOTOR

LIMIT

VALVE

WARNINGElectric shock hazard. High voltage exists at the oil valve plug when the burner switch is in the ON position. High voltage can cause severe injury or death.

Do not touch the receptacles of the electrical plug.


6. Measure the voltage at the electrical plug.

Is 108–132V measured?

7. Place circuit breaker 1 and circuit breaker 2 in the OFF position.8. Measure the resistance between the male terminals on the solenoid body.


9. Position the dip switches back to the original position.

The oil valve has now been checked. If the heating system still does not function, see Section 5.13 Checking the Fuel Filter.

Yes ____ No ____Continue. The wiring to the oil valve has failed. Disconnect the power

supplies and replace the wiring.

Yes ____ No ____The oil valve is OK. The solenoid has failed; replace it.


5.13 Checking the Fuel FilterPrerequisites Power components check OK

Removal procedure

Follow the procedure below to check/change the fuel filter.

1. Place circuit breaker 1 and circuit breaker 2 in the OFF position.2. Locate the fuel filter assembly (a).3. Disconnect both quick-connect couplings (b and c).

Note: There will be fuel in the fuel filter canister. Take measures to capture any fuel that spills. Dispose of this fuel in accordance with local environmental regulations.

4. Remove the bolt (d) from the top of the canister cap and remove the canister cap.

5. Remove the fuel filter (e) and the gasket (f).6. Clean the inside of the canister.

Installation procedure

Follow the procedure below to install the fuel filter.

1. Install a new gasket to the canister.2. Install a new fuel filter into the canister. Be sure to align the fuel filter properly

with the bottom of the canister.3. Re-install the canister cap and secure it with the bolt.4. Reconnect the quick-connect couplings.

The fuel filter has now been checked. If the heating system still does not function, see Section 5.14 Checking the Ignition Transformer.


5.14 Checking the Ignition Transformer

Procedure Follow the procedure below to check the ignition transformer.

1. Open the primary control by loosening screws (a).

2. Position the dip switches (d) in the “down” or “disabled” position.3. Place circuit breaker 1 and circuit breaker 2 in the ON position.4. Place the burner switch in the ON position.

5. Measure the voltage between terminal INTRPT/IGNITER and the wire at L2.



WARNINGElectric shock hazard. High voltage exists at the igniter when the machine is powered. High voltage can cause severe injury or death.

Use caution when working on the ignition transformer.

Yes ____ No ____Continue. Check that the wire from L2 has continuity to neutral of terminal

strip. If it does, the primary control has failed. Shut down the machine and replace the primary control.


6. Place circuit breaker 1 and circuit breaker 2 in the OFF position.7. Loosen tabs (b) and hinge back the igniter plate cover (c).

8. Measure the resistance between the blue/white striped wire and the white wire which are connected to the ignition transformer.

Is approximately 7 megohms measured?

9. Measure the resistance from spring to spring. The springs are located in on the bottom of the igniter plate.


The ignition transformer has now been checked. If the heating system still does not function, see Section 9.1 Setting/Checking the Electrodes.

Yes ____ No ____Continue. The ignition transformer has failed; replace it.

Yes ____ No ____The ignition

transformer is OK.The ignition transformer has failed. Disconnect the power supplies and replace the ignition transformer.


5.15 Checking the ThermocouplePrerequisites Power components check OK

Procedure Follow the procedure below to check the thermocouple.

1. Place circuit breaker 1 and circuit breaker 2 in the ON position.2. Observe the temperature controller.Is the temperature controller displaying the setpoint temperature and the actual temperature as a positive number between 50° and 180°F?


4. Open the control panel and locate the temperature controller.

5. Check the red and blue wires connected to the temperature controller. Clean the wires and terminals if any corrosion is found.


Yes ____ No ____The thermocouple/connections are OK. Continue.




6. Locate the thermocouple housing (a).

7. Remove the cover of the thermocouple housing.8. Check the connections of the wiring. Disconnect the wires and clean the wires

and terminals if any corrosion exists. Reconnect the wires.9. Place circuit breaker 1 and circuit breaker 2 in the ON position.Is the temperature controller displaying the setpoint temperature and the actual temperature as a positive number between 50° and 180°F?

The thermocouple has now been checked. Re-assemble the machine.

Yes ____ No ____The thermocouple/connections are OK. The thermocouple has failed. Disconnect

the power sources and replace the thermocouple.


Circulation System S 3000
6 Circulation System
6.1 Diagnosing the Circulation System

Background There are two types of problems that the circulation system may experience:A mechanical problem with the HTF filter or with the HTF pumpAn electrical problem with a component within the system

Procedure Follow the procedure below to determine the type of circulation problem.

1. Place circuit breaker 2 in the ON position.2. Place the pump switch in the ON position.Does the pump run?

3. Observe the flow meter and pressure gauge.


Yes ____ No ____Continue. See Section 6.2 Troubleshooting the Circulation System

If ThenThere is high pressure and low flow, the hose is pinched or kinked.

Check the hose.There is low pressure and low flow, the HTF filter is clogged, or the pump has failed.

Check the HTF filter (see Section 10.11 Changing/Cleaning the HTF Filter).

If the HTF filter is OK, replace the HTF pump (see Section 10.8 Replacing an HTF Pump).


S 3000 Circulation System
6.2 Troubleshooting the Circulation System
Best practice The best practice when checking the circulation system is to:

1. Isolate and check each component of the heating system individually. 2. When a malfunctioning component is found, repair or replace it.3. After replacing a malfunctioning component, retry system operation.

This chapter of the manual provides procedures to check the components of the circulation system.

Fundamental components

For the circulation pumps to function, the following four fundamental components must function properly.

Pump 1 switchPump 2 switchLow-level shut-down deviceRelay K1

Testing sequence

Check the function of the fundamental components in the sequence below.

Note: If power (108–132 VAC) exists at the pump switches, it means the low-level shut-down device and relay K1 are functioning properly. In such a case, there is no need to test them.

After the fundamental components have been verified, check the pump motor. See Section 6.6 Checking the Pump Motors.

1. Pump 1 switch/Pump 2 switchSee Section 6.3 Checking the Pump Switches.

2. Low-level shut-down deviceSee Section 6.4 Checking the Low-Level Shut-Down Device.

3. Relay K1See Section 6.5 Checking Relay K1.


6.3 Checking the Pump SwitchesPrerequisites Power components check OK
Power connected to the machine

Procedure Follow the procedure below to check the pump switch(es).

1. Open the control panel.2. Place circuit breaker 1 and circuit breaker 2 in the ON position.3. Place the pump switches (a) in the OFF position.

4. Measure the voltage between the incoming side of each pump switch (wire 19 or wire 20) and N2 of the main terminal strip


5. With the each pump switch still in the OFF position, measure the voltage between the outgoing side of each pump switch and N2 of the main terminal strip.





Yes ____ No ____Continue. Relay K1 may have failed. Check relay K1.

Yes ____ No ____The pump switch(es) has failed. Disconnect the power supplies

and replace the pump switch(es).Continue.


6. Place the pump switches in the ON position.7. Measure the voltage between the outgoing side of each pump switch and N2 of

the main terminal strip.Is 108–132 VAC measured?

The procedure to check the pump switches is now complete. If the circulation system still does not function, see Section 6.4 Checking the Low-Level Shut-Down Device.

Yes ____ No ____The pump switches are OK. The pump switch(es) has failed. Disconnect

the power supplies and replace the pump switch(es).


6.4 Checking the Low-Level Shut-Down DevicePrerequisites All power components check OK
Multimeter

Procedure Follow the procedure below to check the low-level shut-down device.

1. Check the level of the HTF on the sight gauge. Add HTF as necessary.

2. Turn off circuit breaker 1 and circuit breaker 2.3. Open the side panel and locate the low-level shut-down device (a).

4. Remove the cover from the low-level shut-down device.5. Remove the wing nut and the probe wire from the probe (b).

6. Measure the resistance between the end of the probe and ground (bare metal location on the heater unit).

Is any resistance measured?


WARNINGElectric shock hazard. High voltage exists inside the low-level shut-down device. High voltage can cause severe injury or death.

Use extreme care when working inside the low-level shut-down device.

Yes ____ No ____Reconnect the probe and continue. The probe has failed; replace it.


7. Turn on circuit breaker 1 and circuit breaker 2.

8. Measure the voltage between wire/terminal black 20 and N2 of the main terminal strip. Also measure between wire/terminal orange 4 and N1 of the main terminal strip.


9. Measure the voltage between the black wire 20 and the white wire/terminal of the low-level shut-down device.


10.Measure the voltage between red wire 5 and N1 of the main terminal strip.Is 108–132 VAC measured?

The low-level shut-down device has now been checked. If the circulation system still does not function, see Section 6.5 Checking Relay K1.



Yes ____ No ____Continue. The wiring (orange 4 or black 20) is faulty. Disconnect the power

supplies and repair the wiring back to the main terminal strip.

Yes ____ No ____Continue. The white wire is faulty. Disconnect the power supplies and repair

the wiring back to the main terminal strip.

Yes ____ No ____The low-level shut-down device is OK.

The low-level shut-down device has failed. Disconnect the power supplies and replace it.


6.5 Checking Relay K1
Prerequisites All power components check OKMultimeter

Procedure Follow the procedure below to check relay K1.


2. Open the control panel.3. Locate relay K1.

4. Label, then disconnect the wires from relay K1.5. Measure the resistance across the coil of the relay, terminals 0 and 1.Is 825–1025 ohms measured?

6. Measure the resistance across normally open contacts terminals 2 and 4.Is approximately 0.1 ohms measured?

7. Measure the resistance across normally open contacts terminals 6 and 8.Is approximately 0.1 ohms measured?








8. Reconnect the wiring to relay K1.

9. Place circuit breaker 1 and circuit breaker 2 in the ON position.10.Measure the voltage between the incoming side of both pump switches (a) and

N2 of the terminal strip.

Is 108–132 VAC measured in both cases?

Relay K1 has now been checked. If the circulation system still does not function, see Section 6.6 Checking the Pump Motors.



Yes ____ No ____Rely K1 is OK. Relay K1 has failed. Disconnect the power

sources and replace relay K1.


6.6 Checking the Pump MotorsPrerequisites Power components check OK

Procedure Follow the procedure below to check either pump motor.

1. Start this test with circuit breaker 1 and circuit breaker 2 in the OFF position.2. Locate the pumps.

Note: Several different styles of motors have been used. Your motors may differ slightly from those shown.

3. Remove the cover plate from the junction box.


WARNINGElectric shock hazard. High voltage exists inside the pump motor junction boxes. High voltage can cause severe injury or death.

Use extreme care when working inside the pump motor junction boxes.


4. Disconnect white wire 9.

5. Place circuit breakers 1 & 2 in the ON position.6. Measure the voltage between black wire (7 or 8 depending on the pump) of the

pump and N2 of the main terminal strip.Is 108–132 VAC measured?

7. Measure the voltage between white wire 9 and black wire 7 or 8.Is 108–132 VAC measured?

The pump motor(s) have now been checked. Re-assemble the machine.

WARNINGElectric shock hazard. High voltage exists inside the pump motor junction boxes. High voltage can cause severe injury or death.

Use extreme care when working inside the pump motor junction boxes.

Yes ____ No ____Continue. The wiring to the pump motor has failed. Disconnect the power


Yes ____ No ____The pump motor has failed. Disconnect the power supplies and replace the pump motor.

White wire 9 has failed. Disconnect the power supplies and repair the wiring.


Rewind System S 3000
7 Rewind System
7.1 Troubleshooting the Rewind System

Best practice The best practice when troubleshooting the rewind system is to:

1. Isolate and check each component of the rewind system individually. 2. When a malfunctioning component is found, repair or replace it.3. After replacing a malfunctioning component, retry system operation.

This chapter of the manual provides procedures to check the components of the rewind system.

Mechanical components

When diagnosing rewind system problems, first rule out problems with the mechanical components.

For all other scenarios, see the chart below.

Electrical components

Check the electrical components in the sequence listed below.

If ThenThe rewind motor runs and the rewind clutch solenoid activates (a distinct click can be heard), but the system still won’t function,

there is a mechanical problem. See Section 7.9 Checking the Rewind System Mechanical Components.

1. Fuse 1 and Fuse 2See Section 7.2 Checking Fuse 1 and Fuse 2.

2. RectifierSee Section 7.3 Checking the Rectifier.

3. Rewind transformerSee Section 7.4 Checking the Rewind Transformer.

4. Foot switchSee Section 7.5 Checking the Foot Switch.

5. Hose rewind switchSee Section 7.6 Checking the Rewind Switch.

6. Rewind clutch solenoidSee Section 7.7 Checking the Rewind Clutch (Solenoid).

7. Rewind motorSee Section 7.8 Checking the Rewind Motor.


S 3000 Rewind System
7.2 Checking Fuse 1 and Fuse 2
Prerequisites Power supplies disconnectedReplacement fuses if necessary

Procedure Follow the procedure below to check fuse 1 and fuse 2.

1. Disconnect the power supplies.

2. Open the control panel.3. Open the cover (a) for fuse 1 and inspect fuse 1.

4. Replace fuse 1 if it is blown, or re-install fuse 1.5. Repeat the procedure for fuse 2 (b).

Fuse 1 and fuse 2 have now been checked. If the rewind system still does not function, see 7.3 Checking the Rectifier.


Disconnect the power supplies before conducting this test.


7.3 Checking the Rectifier
Prerequisites Power components check OKRewind transformer checks OK

Procedure Follow the procedure below to check the rectifier.

1. Start this test with circuit breaker 1 in the OFF position.

2. Open the control panel and locate the rectifier (a).

3. Place circuit breaker 1 in the ON position.4. Measure the voltage between terminal 22 and terminal 24 of the main terminal

strip.Is 10–17 VAC measured?

5. Measure the DC voltage between terminal 14 and terminal 16.Is 10–17 VDC measured?

The rectifier has now been checked. If the rewind system still does not function, see Section 7.4 Checking the Rewind Transformer.



Yes ____ No ____Continue. The wiring between the rewind transformer and the terminal strip

has failed. Disconnect the power supplies and repair the wiring.

Yes ____ No ____The rectifier is OK. The rectifier has failed. Disconnect the

power supplies and replace the rectifier.


7.4 Checking the Rewind Transformer
Prerequisites Power components check OKFuse 2 checks OK

Procedure Follow the procedure below to check the rewind transformer.

1. Start this test with circuit breaker 1 and circuit breaker 2 in the OFF position.2. Open the control panel and locate the rewind transformer (a).





3. Place circuit breaker 1 in the ON position.4. There are two black wires 21 connected to the rewind transformer. Measure the

AC voltage between one of the black wires 21 and N1 of the terminal strip. Measure the AC voltage between the other black wire 21 and N1 of the terminal strip.


5. Measure the AC voltage between terminal/wire 23 and terminal/wire 24 of the rewind transformer.


The rewind transformer has now been checked. If the rewind system still does not function, see Section 7.5 Checking the Foot Switch.

Yes ____ No ____Continue. The wiring between fuse 1and the rewind transformer has failed.


Yes ____ No ____The rewind

transformer is OK.The rewind transformer has failed. Disconnect the power supplies and replace the rewind transformer.


7.5 Checking the Foot Switch
Prerequisites Power components check OKRewind transformer checks OKRectifier checks OK

Procedure Follow the procedure below to check the foot switch.

1. Start this test with circuit breaker 1 in the OFF position.

2. Open the control panel.3. Place circuit breaker 1 in the ON position.4. Step on (or close) the foot switch.

5. Measure the resistance between terminal 14 and terminal 15 of the main terminal strip while stepping on the foot switch.

Is approximately 0.1 ohms measured?

6. Measure the resistance between terminal 14 and terminal 15 of the main terminal strip while not stepping on the foot switch.

Does your meter read OPEN or OL?




Yes ____ No ____Continue. The wiring or the foot switch has failed. Disconnect the power

supplies and repair the wiring or replace the foot switch.

Yes ____ No ____Continue. The wiring or the foot switch has failed. Disconnect the power

supplies and repair the wiring or replace the foot switch.


7. Measure the DC voltage between terminals 15 and 16 of the terminal strip while stepping on the foot switch.

Is 10–17 VDC measured?

The foot switch has now been checked. If the rewind system still does not function, see section 7.6 Checking the Rewind Switch.

Yes ____ No ____The foot switch is OK. The foot switch has failed. Disconnect the

power supplies and replace the foot switch.


7.6 Checking the Rewind SwitchPrerequisites Power components check OK
Fuse 1 checks OK

Procedure Follow the procedure below to check the rewind switch.

1. Place circuit breaker 1 in the ON position.2. Place the rewind switch in the ON position.Does the rewind motor run?

3. Open the control panel.4. Measure the voltage between the incoming side (wire 21) of the rewind switch

(a) and N1 of the main terminal strip.


5. With the rewind switch still in the OFF position, measure the voltage between terminal/wire 6 on the outgoing side of the rewind switch and N1 of the main terminal strip.



Yes ____ No ____The rewind switch is OK. Continue.



Yes ____ No ____Continue. The wiring between fuse 1 and the rewind switch has failed.


Yes ____ No ____The rewind switch has failed. Disconnect the power supplies

and replace the rewind switch.Continue.


6. Place the rewind switch in the ON position.7. Measure the voltage between terminal/wire 6 on the outgoing side of the rewind

switch and N1 of the main terminal strip.Is 108–132 VAC measured?

The rewind switch has now been checked. If the rewind system still does not function, see Section 7.7 Checking the Rewind Clutch (Solenoid).

Yes ____ No ____The rewind switch is OK. The rewind switch has failed. Disconnect

the power supplies and replace the rewind switch.


7.7 Checking the Rewind Clutch (Solenoid)Prerequisites Power components check OK
Fuse 1 checks OKFuse 2 checks OK

Procedure Follow the procedure below to check the rewind clutch solenoid.

1. Open the control panel.

2. Place circuit breaker 1 in the ON position.3. Step on (or close) the foot switch and measure the DC voltage between

terminals 15 and 16.

Is 10–16 VDC measured?

4. Place circuit breaker 1 in the OFF position.5. Measure the resistance across terminal 15 and terminal 16.Is 2.2–4.2 ohms measured?

The rewind clutch solenoid has now been checked. If the rewind system still does not function, see section 7.8 Checking the Rewind Motor.



Yes ____ No ____Continue. One of the following components has failed:

rewind transformer, rectifier, or foot switch.

Yes ____ No ____The rewind clutch solenoid is OK. The rewind clutch solenoid has failed;

replace it.


7.8 Checking the Rewind Motor
Prerequisites Power components check OKRewind switch checks OK

Procedure Follow the procedure below to check the rewind motor.

1. Start this test with circuit breaker 1 in the OFF position.2. Locate the rewind motor (a).Note: Graphic for reference only; your machine may differ from that shown.



3. Remove the cover (b) of the rewind motor in question.

4. Disconnect white wire 2.5. Place circuit breaker 1 in the ON position.6. Place the rewind switch in the ON position.7. Measure the voltage between black wire 6 and N1 of the terminal strip.


8. Measure the voltage between black wire 6 and white wire 2.


The rewind motor has now been checked. Re-assemble the machine.

WARNINGElectric shock hazard. High voltage exists inside the rewind motor. High voltage can cause severe injury or death.

Use extreme care when working inside the rewind motor.

Yes ____ No ____Continue. The wiring between the rewind switch and the rewind motor has

failed. Disconnect the power supplies and repair the wiring.

Yes ____ No ____The rewind motor has failed. Disconnect the power supplies and replace the rewind motor.

White wire 2 has failed. Disconnect the power supplies and repair white wire 2.


7.9 Checking the Rewind System Mechanical ComponentsPrerequisites Power supplies disconnected
Machine cool

Procedure Follow the procedure below to check the rewind system mechanical components.

1. Remove the chain guard (a) or side panels to access the system.

2. Inspect all the mechanical components: chain, gears, keys, bearings, etc.3. Replace all damaged or missing components.

WARNINGPinching/crushing hazard. Moving parts of the rewind system can pinch or crush.

Disconnect the power supplies before checking the mechanical components.


S 3000 Miscellaneous Components
8 Miscellaneous Components
8.1 Checking an Indicator LightPrerequisites Power components check OK

K3 relay checks OK

Procedure Follow the procedure below to check an indicator light.

1. Start this test with circuit breaker 1 and circuit breaker 2 in the OFF position.

2. Simulate a burner fault by removing the cad cell from burner.3. Place the burner switch in the ON position.

4. Open the control panel.5. Locate the indicator light to be tested.6. Simulate a low level fault by placing only circuit breaker 1 in the ON position.Do the indicator lights illuminate?

7. Measure the voltage between the incoming side (black wire 27 or 29) of the indicator light and N1.


8. Check the resistance (continuity) of the white wire back to the terminal strip.Does the white wire have continuity?

The indicator light has now been checked. Re-assemble the machine.



Yes ____ No ____The indicator lights are OK. Continue.

Yes ____ No ____Continue. The wiring to the indicator light has failed. Disconnect the power


Yes ____ No ____The indicator light has failed. Disconnect the power supplies and replace the indicator light.



Miscellaneous Components S 3000
8.2 Checking the Fuel Prewarmer
Prerequisites Power components check OKHeating system fundamental components check OK

Procedure Follow the procedure below to check the fuel prewarmer.


2. Loosen tabs (b) and hinge back the igniter plate cover.3. Disconnect the fuel prewarmer.

4. Measure the resistance of the fuel prewarmer at the connector (d).Is 210–220 ohms measured?


Yes ____ No ____Continue. The fuel prewarmer has failed. Disconnect the power supplies and

replace the prewarmer.


S 3000 Miscellaneous Components
5. Place circuit breakers 1 and circuit breaker 2 in the ON position.

6. Place the burner switch in the ON position.7. Measure the voltage between the two wires of the connector (e).


The procedure to check the fuel prewarmer is now complete.

WARNINGElectric shock hazard. High voltage exists on the fuel prewarmer when the burner switch is in the ON position. High voltage can cause severe injury or death.

Use extreme care when working on the fuel prewarmer.

Yes ____ No ____The fuel prewarmer is OK. The wiring to the fuel prewarmer has failed.

Disconnect the power supplies and replace the wiring.


Miscellaneous Components S 3000


S 3000 Burner Setup
9 Burner SetupFactory settings
Background The burner consists of several different components and subsystems. Each of these components or subsystems must be operating correctly for the burner to function properly.

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.

Tools required The following tools are required to adjust the burner:High-quality combustion analyzer Smoke spot testerFuel pressure test gaugeGeneral hand tools

Mandates Adjustments made shall be done so that the machine conforms to the require-ments of local, state, and federal codes and authorities. Adjustments shall be made at the job site.


Head Firing rateL/hr (gph) Nozzle size Fuel pressure

bar (psi)Air bandsetting

Air shutter

F22 8.8 (2.0) 1.65 80° B 10.0 (145) 4 0

Fuel Blend GuideLowest expected ambient

temperature °F (°C) Generator powered Shore powered

Below 5 (-15)

50-50 blend of #2 diesel and #1 diesel, plus

additivesOR

50-50 blend #2 diesel and K1 kerosene, plus

additives

100% #1 diesel plus additives

OR100% K1 kerosene,

plus additives

5 to 25 (-15 to -4)70-30 blend of #2 diesel and #1 diesel, plus additives

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

plus additives

Above 25 (-4) Winter-blend diesel


Burner Setup S 3000
When Adjust the burner:Before operating the machine at elevations 305 m (1,000 ft) above or below the location of where the last adjustments were made.Before starting at a new job site.After any burner maintenance or repair has been performed.If burner performance is in question.

Procedure Follow the procedures below to set up the burner.

1. Shut down the machine.2. Set the burner electrodes.

(See Section 9.1 Setting/Checking the Electrodes on page 89.)

3. Check the burner nozzle.(See Section 9.2 Replacing the Burner Nozzle on page 91.)

4. Check/set the “Z” distance.(See Section 9.3 Setting the “Z” Distance (“F” head) on page 94.)

5. Set the air settings.(See Section 9.4 Adjusting the Air Settings on page 96.)

6. Start the machine and the burner.7. Check/set the fuel pressure.

(See Section 9.5 Setting the Fuel Pressure on page 97.)

8. Conduct a smoke spot test. Follow the smoke spot tester manufacturer’s instructions and the general guidelines below.

Use the access hole in the exhaust stack.Several samples should be taken as the heater warms.The final sample should be taken just before the heater reaches 71°C (160°F).



S 3000 Burner Setup
9. Analyze the combustion. Follow the combustion analyzer manufacturer’s instructions and the general guidelines below.

Use the access hole in the exhaust stack.Take several samples as the heater warms. Take the final sample just before the heater reaches 71°C (160°F).

10.Re-adjust the air setting(s) if necessary until the smoke spot test and combustion analysis are within the following parameters:O2 content: 4–6% Smoke spot: 1 or less

Result You have now setup the burner.

Background The burner consists of several different components and subsystems. Each of these components or subsystems must be operating correctly for the burner to function properly.

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 GuideLowest expected ambient

temperature °F (°C) Generator powered Shore powered

Below 5 (-15)

50-50 blend of #2 diesel and #1 diesel, plus

additivesOR

50-50 blend #2 diesel and K1 kerosene, plus

additives

100% #1 diesel plus additives

OR100% K1 kerosene,

plus additives

5 to 25 (-15 to -4)70-30 blend of #2 diesel and #1 diesel, plus additives

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

plus additives


Burner Setup S 3000

Tools required The following tools are required to adjust the burner:High-quality combustion analyzer Smoke spot testerFuel pressure test gaugeGeneral hand tools

Mandates Adjustments made shall be done so that the machine conforms to the require-ments of local, state, and federal codes and authorities. Adjustments shall be made at the job site.


Above 25 (-4) Winter-blend diesel

Fuel Blend Guide


S 3000 Burner Setup
When Adjust the burner:Before operating the machine at elevations 305 m (1,000 ft) above or below the location of where the last adjustments were made.Before starting at a new job site.After any burner maintenance or repair has been performed.If burner performance is in question.

Procedure Follow the procedures below to set up the burner.

1. Shut down the machine.2. Set the burner electrodes.

(See Section 9.2 Setting/Checking the Electrodes on page 99.)

3. Check the burner nozzle.(See Section 9.3 Checking/Replacing the Nozzle on page 101.)

4. Check/set the “Z” distance.(See Section 9.4 Setting the “Z” Distance (“L” head) on page 104.)or(See Section 9.5 Setting the “Z” Distance (“F” head) on page 105.)

5. Set the air settings.(See Section 9.6 Adjusting the Air Settings on page 107.)

6. Start the machine and the burner.7. Check/set the fuel pressure.

(See Section 9.7 Setting the Fuel Pressure on page 108.)

8. Conduct a smoke spot test. Follow the smoke spot tester manufacturer’s instructions and the general guidelines below.

Use the access hole in the exhaust stack.Several samples should be taken as the heater warms.The final sample should be taken just before the heater reaches 71°C (160°F).



Burner Setup S 3000
9. Analyze the combustion. Follow the combustion analyzer manufacturer’s instructions and the general guidelines below.

Use the access hole in the exhaust stack.Take several samples as the heater warms. Take the final sample just before the heater reaches 71°C (160°F).

10.Re-adjust the air setting(s) if necessary until the smoke spot test and combustion analysis are within the following parameters:O2 content: 4–6% Smoke spot: 1 or less

Result You have now setup the burner.


S 3000 Burner Setup
9.1 Setting/Checking the ElectrodesPrerequisites Power supplies disconnected
Measuring device

Procedure Follow the procedure below to check the electrodes. Note: Procedure shows the “F” head.

1. Disconnect the power supplies.2. Remove the copper fuel line (a) between the fuel pump and the burner housing.Note: Only remove the fuel fitting closest to the burner housing.

3. Remove the knurl nut (b) that is seated against the escutcheon plate.NOTICE: Handle the knurled knob with care. It is easily damaged.

4. Loosen tabs (c) and hinge back the igniter cover..

5. Disconnect the wiring to the electrode assembly.6. Maneuver the electrode assembly (d) up and out of the burner.



Burner Setup S 3000
7. Use the measurements below to properly set the electrode tips on both the “F” and the “L” head.

Note: Beckett also has special tools for measuring the “Z” distance:The Beckett “Z” gauge may be used on “F” heads.The Beckett T501 gauge may be used on both “F” and “L” heads.

Result You have now checked/adjusted the electrodes.

Ref. Description Gap distanceh Electrode tip to electrode tip 5/32 in. (4 mm)

i Nozzle center to electrode tip 5/16 in. (7.5 mm)

j Nozzle end to electrode tip end 1/16 in. (1.5 mm)


S 3000 Burner Setup
9.2 Replacing the Burner Nozzle
Prerequisites Power supplies disconnectedMachine cool

Removal Follow the procedure below to remove the burner nozzle.

1. Disconnect the power supplies.2. Remove the copper fuel line (a) between the fuel pump and the burner housing.

3. Remove the knurl nut (b) that is seated against the escutcheon plate.Note: Handle the knurled knob with care. It is easily damaged.

4. Loosen tabs (c) and hinge back the igniter cover..

5. Disconnect the preheater wiring.6. Maneuver the electrode assembly (d) up and out of the burner.



Burner Setup S 3000
7. Unscrew the burner nozzle from the burner tube.

The procedure to remove the burner nozzle is now complete.

Installation Follow the procedure below to install the burner nozzle.

1. Thread the new burner nozzle into the burner tube.Note: Do not use thread sealant on the threads.

2. Position the igniter assembly (d) into the burner.

3. Connect the preheater wiring.4. Close the igniter cover and secure it with tabs (c).



S 3000 Burner Setup
5. Install the knurl nut (b) that is seated against the escutcheon plate.Note: Handle the knurled knob with care. It is easily damaged.

6. Install the copper fuel line (a) between the fuel pump and the burner housing.

Result You have now replaced the nozzle.


Burner Setup S 3000
9.3 Setting the “Z” Distance (“F” head)
Prerequisites Burner removed from the machineT501 gauge or “Z” gauge

Procedure Follow the procedure below to set the “Z” distance on F-style heads.

1. Remove the burner from the machine.2. Loosen the knurled nut (b).

3. Loosen the position locking screw (e).4. Set the “Z” distance by using one of the three following methods: using Beckett

T501 gauge, by measuring, or using Beckett “Z” gauge.

Beckett T501 gauge

Using the Beckett T501 gauge.

a. Position the gauge into the flame retention head as shown.

b. Slide the nozzle assembly so that the front face of the burner nozzle touches the T501 gauge.

c. Tighten the position locking screw.d. Tighten the knurled nut.e. Mark the escutcheon plate for later reference. See step 5.



S 3000 Burner Setup
Measuring Measuring the “Z” distance.

a. Place a straight edge over the end of the flame retention head.

b. Adjust the nozzle assembly until the distance between the front face of the burner nozzle and the end of the head measures 1-1/8 inches (28 mm).

c. Tighten the position locking screw (e).d. Tighten the knurled nut.f. Mark the escutcheon plate for later reference. See step 5.

Beckett “Z” gauge

The Beckett “Z” gauge may also be used. Refer to the Beckett instructions for detailed information.

5. Mark (x) the escutcheon plate for later reference.

Result You have now set the “Z” distance.

x


Burner Setup S 3000
9.4 Adjusting the Air Settings
Background There are two parts to the adjusting the air setting: 1) air band; and 2) air shutter. Adjust the air band to make large adjustments. Adjust the air shutter to make small adjustments.

Affects The air setting has the following effect on combustion.Higher O2 percentage (excess air settings) lowers soot production but raises stack temperature and reduces efficiency: lean mixture.Lower O2 percentage (inadequate air settings) increases efficiency and lowers stack temperature but may cause soot build-up: rich mixture.

Procedure Follow the procedure below to adjust the air settings.

1. Initial setting of the air damper should be performed with the machine shut down.

2. Loosen the air band locking screw (a) and the air shutter locking screw (b).

3. Using the band position pointer (c) to determine position, move the air band to a higher number to increase air volume. Turn it to a lower number to decrease air volume.

4. Using the shutter position pointer (d) to determine position, move the air shutter to a higher number on the shutter position pointer to increase air volume. Turn it to a lower number to decrease air volume.

5. After the air settings have been made, tighten the band-locking screw (a) and the shutter-locking screw (b).

Result You have now adjusted the air settings.


S 3000 Burner Setup
9.5 Setting the Fuel PressureFactory setting
Factory settings:“F” head: 145 psig (10.0 bar)“L” head: 180 psig (12.4 bar)

Procedure Follow the procedure below to check and adjust the fuel pressure.

1. Shut down the machine.2. Remove the bleeder valve (a) from the fuel pump.

3. Insert the gauge in place of the bleeder valve.4. If your machine has a generator, start it.5. Turn the control switch to HEAT. The burner will go through a pre-purge cycle.

Monitor and make adjustments during the pre-purge cycle.6. Turn the adjusting screw (b) clockwise to increase fuel pressure,

counterclockwise to decrease fuel pressure.

Result You have now adjusted the fuel pressure.


Disassembly and Assembly S 3000 Repair
10 Disassembly and Assembly
10.1 Tools Required for Disassembly/Assembly ProceduresIt is up to the mechanic to use common sense and good judgment in tool selection to reduce the risk of injury while repairing the machine. In cases where a special tool is required, the special tool is listed in the prerequisite section of the procedure.Before substituting another tool or procedure from those recommended in this manual, the mechanic must be satisfied that neither personal injury nor damage to the machine will result due to the substitution.

10.2 Information Regarding Replacement PartsThe repair procedures contained in this manual do not include part numbers. For replacement parts information, refer to the Parts Book originally supplied with the machine. If the original Parts Book has been lost, a replacement may be ordered from Wacker Neuson Corporation. When ordering a replacement Parts Book, please list the model number, item number, revision level, and serial number of the machine. Parts Books are also available on the Wacker Neuson Corporation Web site. See www.wackerneuson.com. Enter the site as a visitor.

10.3 Information Regarding Reference NumbersRepair procedures contain reference numbers enclosed in parentheses ( ). These numbers refer to the item numbers shown on the assembly drawings and other detailed drawings. They are included to aid the mechanic in identifying parts and assembling components.


S 3000 Repair Disassembly and Assembly
10.4 Removing the BurnerPrerequisites Power supplies disconnected
Machine cool

Procedure Follow the procedure below to remove the burner.

1. Disconnect the power supplies.2. Disconnect fuel lines (a) at the quick-connects.

3. Remove the primary control (b) to expose the wiring. Label all the wires to assist in reconnecting.

4. Disconnect all wires coming from the snap switch cable (c).

Note: The snap switch cable is a large black insulated wire that enters the electri-cal enclosure from the rear.

5. Disconnect all wires coming from the burner cable (d).

Note: The burner cable is a large black insulated wire that enters the electrical enclosure from the left side.

6. Remove the screws that secure the burner to the machine and maneuver the burner from the machine.

The procedure to remove the burner is now complete.


10.5 Installing the BurnerPrerequisites Power supplies disconnected
Machine cool

Procedure Follow the procedure below to install the burner.

1. Position the burner inside the machine and secure it to the hydronic heater.

2. Connect fuel lines (a) at the quick-connects.

3. Install the primary control (b).4. Connect all wires coming from the burner cable (d).

5. Connect all wires coming from the snap switch cable (c). The procedure to install the burner is now complete.


10.6 Replacing the Fuel PumpPrerequisites Machine shut down
Burner removed from machine

Removal Follow the procedure below to remove the fuel pump.

1. Remove the solenoid power cord (a).

2. Remove the copper fuel line (b).3. Remove the pump mounting screws (c). Save them for later use.

4. Pull the pump away from the burner housing. This exposes the drive coupling (d). Save the drive coupling for later use.



5. Remove both fuel line assemblies and hose barbs (e) from the fuel pump. Save them for later use.

6. Remove the bypass plug (set screw) from the return port (f). Save it for later use.

The procedure to remove the fuel pump is now complete.

Installation Follow the procedure below to install the fuel pump.

1. Install the bypass plug (set screw) into the return port (f).

NOTICE: To avoid damage to the fuel pump, the bypass plug must be installed. Re-use the bypass plug from the old fuel pump or use the bypass plug shipped with the new fuel pump.

2. Apply thread sealant to the hose barbs (e) and install the fuel line assemblies into the proper ports.

Note: Install the fuel line with the attached fuel filter into the “SUPPLY” port.

3. Mount the new pump onto the burner housing. Take care to align the new pump shaft into the drive coupling.



4. Use the old screws (c) to secure the pump to the burner housing.

5. Reconnect the copper fuel line (b) onto the new pump.

6. Reconnect the existing solenoid power cord (a) onto the new pump.

The procedure to replace the fuel pump is now complete.


10.7 Replacing the Burner Fan Motor
Prerequisites Machine shut downBurner removed from machine

Removal Follow the procedure below to remove the burner fan motor.


2. Locate and remove the orange wire and white wire that power the burner fan motor from the primary control.

3. Pull the orange wire and white wire from the junction box.

4. Remove the burner fan motor assembly from the burner housing.

Note: Be careful not to pull out the fuel pump coupling when removing the burner fan motor.


CAD CELL

L1

L2

L2

L2

L2

INTRPT/IGNITER

2

BURNER/MOTOR

LIMIT

VALVE


5. Loosen the set screw and remove the fan (a). Save the fan for reuse.

The procedure to remove the burner fan motor is now complete.

Installation Follow the procedure below to install the burner fan motor.

1. Install the fan (a) onto the burner fan motor shaft (tighten the set screw onto the flat of the shaft).

2. Install the burner fan motor assembly (b) to the burner housing.3. Route the orange wire and the white wire into the junction box.4. Connect the orange wire to the BURNER MOTOR terminal of the primary

control.5. Connect the white wire to the L2 terminal of the primary control.6. Reconnect the primary control.

The procedure to install the burner fan motor is now complete.


10.8 Replacing an HTF Pump
Prerequisites Power supplies disconnectedMachine cool

Removal Follow the procedure below to remove the pump.

1. Disconnect the power supplies.2. Disconnect the pump 1 quick-connect (a).

3. Close valve 2 (b) located between the hydronic heater and the fluid filter.4. Loosen the female swivel fittings (c) that connect the discharge and supply

lines.

5. Remove the pump mounting bolts and remove the pump (d) from the motor adapter (f).



6. Remove the Lovejoy coupling (e) from the pump shaft. Save the Lovejoy coupling for reuse.

The procedure to remove the pump is now complete.

Installation Folow the procedure below to install the pump.

1. Install the old Lovejoy coupling (e) onto the shaft of the new pump. Make sure to tighten the set screw against the flat of the pump shaft.

2. Align the two halves of the Lovejoy coupling and install the new pump onto the motor adapter (f).



3. Use a 1-1/4" wrench to tighten the fittings (c) onto the new pump.

4. Open valve 2 (b).5. Reconnect the pump 1 quick-connect (a).

The procedure to replace the pump is now complete.


10.9 Changing a Turbulator/Cleaning a Turbulator TubePrerequisites Machine shut down
Machine cool

Procedure Follow the procedure below to clean/change the turbulator tubes.

1. Allow the machine to cool.

2. Remove the nuts (a) that secure the flue box door.

3. Open the flue box door (b). NOTICE: If the door panel insulation does not open with the door, carefully remove it from where it is caught on the bolts (c).

4. Locate the turbulators housed in the burner tubes.

5. Remove the turbulators (d) by pulling the turbulator tab. Replace any turbulator that is badly corroded.

6. Clean each burner tube with a bottle brush. 7. Vacuum out each burner tube.The procedure is now complete. Re-assemble the machine.

WARNINGBurn hazard. The hydronic heater is very hot when the machine is operating. When hot it can cause severe burns.

Allow the machine to cool before performing this procedure.


10.10 Repairing a Hose
Prerequisites Hose nippleTwo hose ferrulesHose crimping tool part number 169002

Procedure Follow the procedure below to repair a damaged hose.

1. Shut down the machine and allow the Heat Transfer Fluid (HTF) to cool.2. Locate the damaged portion of the hose and clamp locking pliers on either side

of the damaged portion.3. Cut away the damaged portion of the hose (a) using a utility knife or similar tool.

4. Install a ferrule (b) on either end of the freshly cut hose.5. Install the nipple (c) into one of the hoses. NOTICE: Do not use petroleum to lubricate the nipple. If lubrication is needed, use HTF.

6. Install the nipple into the second hose with ferrule. Be sure to push each end of each hose to the lip of the nipple.



7. Use a Wacker Neuson brand hose crimper (e) to crimp both ferrules.



10.11 Changing/Cleaning the HTF Filter
Prerequisites Machine shut downMachine cool

Removal Follow the procedure below to remove the Heat Transfer Fluid (HTF) filter.

1. Shut down the machine and allow the HTF to cool.2. Close valve 2 (a) and valve 3 (b).

Note: HTF may spill when changing the filter. Do not allow the HTF to spill on the ground. Clean up spilled HTF immediately. Dispose of the HTF and soiled rags in accordance with local environmental regulations.

3. Remove the bolt (c) from the top of the filter head (d) and separate the filter head from the bowl (e).

4. Remove and inspect the filter (f) and the gaskets (g). Discard a damaged filter or gaskets.

5. If reusing the filter or gaskets, wash them thoroughly with tap water.

The procedure to remove the filter is now complete.



Installation Follow the procedure below to install the HTF filter.

1. Install gaskets (g) to the filter (f).

2. Place the filter and gaskets into the bowl (e).3. Install the assembly using bolt (c).

The procedure to change the HTF filter is now complete.


10.12 Changing Low Level Probe
Prerequisites Machine shut downHeat Transfer Fluid (HTF) drained

Removal Follow the procedure below to remove the low-level probe.

1. Drain the HTF from the machine. See the Operator’s Manual.2. Open the side panel and locate the low-level shut-down device (a). Remove the

cover from the low-level shut-down device.

3. Disconnect the wire (b) to the low-level probe.4. Loosen the screws (c) that secure the low-level shut-down device.

5. Rotate the low-level shut-down device and pull it from the machine.



6. Unscrew the low-level probe and remove it from the hydronic heater.

The procedure to remove the low-level probe is now complete.

Installation Follow the procedure below to install the low-level probe.

1. Apply thread sealant to all but the first three threads of the low-level probe.2. Screw the low-level probe into the hydronic heater.NOTICE: Use care when installing the low-level probe to avoid damaging it.

3. Align the two screws of the low-level probe so that they are level (horizontal to the ground).

4. Attach the low-level shut-down device to the low-level probe and tighten screws (c).

5. Re-install the wire to the low-level probe.6. Re-install the cover to the low-level shut-down device.7. Refill the machine with HTF. See the Operator’s Manual.

The procedure to replace the low-level probe is now complete.


10.13 Replacing the ThermocouplePrerequisites Machine shut down
Machine cool

Removal Follow the procedure below to remove the thermocouple.

1. Remove the canister lid (a) from the thermocouple body.

2. Loosen the strain relief (b).3. Disconnect the wiring (c).4. Unscrew the thermocouple (d) from the well in the hydronic heater.The procedure to remove the thermocouple is now complete.

Installation Follow the procedure below to install the thermocouple.

1. Screw the thermocouple (d) into the well of the hydronic heater.2. Thread the wiring (c) through the strain relief and connect it to the

thermocouple.3. Tighten the strain relief (b).4. Install the canister lid (a).

The procedure to replace the thermocouple is now complete.


S 3000 Repair Schematics
11 Schematics
11.1 S 3000 Composite Schematic


Schematics S 3000 Repair
11.2 S 3000 Composite Components
Use the following table of symbols for the schematics found throughout this chapter.

Symbol Ref DescriptionCB1 Circuit breaker 1

GFCI 1 Ground Fault Circuit Interrupt 1

FU1 Fuse 1

HOSE REWIND

Hose rewindOff/On switch

MTR Rewind motorPump motorBurner motor

FU2 Fuse 2

n/a Rewind transformer

n/a n/a To line 26

n/a n/a To line 27

RECT1 Rectifier

FTSW1 Foot switch 1

SOL1 Solenoid 1 (rewind clutch)

n/a n/a From line 17

n/a n/a To line 18

n/a n/a To line 12

n/a n/a To line 26

n/a n/a To line 27

LOW LEVEL Low-level shut-down devicepower connection terminals

LOW LEVEL Low-level shut-down devicenormally open contacts

8

-8



n/a n/a Pumps, enable

n/a n/a Pump pack

K1 Relay coil (K1)

K1 Relay normally open contacts (K1)

K2 Relay coil (K2)

K2 Relay normally closed contacts (K2)

K2 Relay normally open contacts (K2)

PL1 Pilot light 1Low level fault

PL2 Pilot light 2Burner fault

HOUR METER

Hour meter

n/a Ignition transformer

n/a n/a Blower

n/a n/a Limit

n/a n/a Alarm

n/a n/a Burner controller (primary control)

SOL 2 Solenoid 2(Oil valve)

T/C type T Thermocouple Type T

TEMP. CONT-ROLLER

Temp. (temperature) controller

n/a Cab light

CAB LIGHT Cab lightOff/On switch

CB 2 Circuit breaker 2

Symbol Ref Description



GFCI 2 Ground Fault Circuit Interrupt 2

PUMP 2 Pump 2Off/On switch

PUMP 1 Pump 1Off/On switch

GND Ground

TS1 Thermal switch 1 (snap disc)

HTR1 Heater (fuel prewarmer)

CAD Cad cell

LOW LEVEL OVERRIDE

MOMENTARY

Low-level shut-down device momentary override Off/On switch.

BURNER BurnerOff/On switch

n/a REWIND Rewind

Symbol Ref Description


11.3 Heating System Circuit

11.4 Circulation System Circuit

11.5 Rewind System Circuit



S 3000 Repair Technical Data
12 Technical Data
12.1 S 3000

S 3000 Units Item No. 0620182

Item No.0620218

Weight, no fuel, no generator kg (lb) 2417 (5330)

Weight, full fuel, no generator kg (lb) 3000 (6614)

Generator weight kg (lb) n/a 238 (525)

Fuel tank capacity L (gal) 674 (178)

Hose length m (ft) 914 (3000)

HTF capacity L (gal) 423 (112)

HTF Pump L/hr (gph) 2 X 1003 (2 X 265)

Burner nozzle gph X deg 1.65 80° A

Fuel pressure bar (psi) 10 (145)

Fuel input kW/hr (BTU)/hr

82(280,000)

Heat output kW/hr(BTU)/hr

70(240,000)

Heater efficiency % 85

Run time (up to) hr 120

Hose pressure bar (psi) 6.2–7.5 (90–110)

Standard thaw capacity m2 (ft2) 279–418 (3000–4500)

Standard cure capacity m2 (ft2) 558 (6000)

ghi_td000302gb.fm 125

Technical Data S 3000 Repair
12.2 Dimensions
cm (in.)

ghi_td000302gb.fm 126

S 3000 Repair Appendix
13 Appendix
13.1 Omron Temperature Controller ProgrammingO

MR

ON

E5C

N &

E5G

N D

IGIT

AL

TEM

PE

RA

TUR

E C

ON

TRO

L P

RO

GR

AM

MIN

G

12

34

5

67

89

10

1112

MO

DEL

V60

E300

0

E220

0E1

700

E110

0AB

-XHD

AB-H

DMC

5200

Pure

heat

S300

0

HYS 10.0

10.0

10.0

10.0

10.0 5.0 5.0 10.0

10.0

10.0

SL-H

180

180

180

180

180

210

210

180

180

180

SL-L 50 50 50 50 50 50 50 50 5050

Red I

nsula

tion (

-)TY

PE J

THER

MOCO

UPLE

Whit

e Ins

ulatio

n (+)

Blue

Insu

lation

(+)

Red I

nsula

tion (

-)

TYPE

TTH

ERMO

COUP

LE

Pres

s onc

e, us

e arro

w ke

ys to

set

the up

per li

mit to

180°

OM

RO

NE

5CNPV SV

OUT

1

Pres

s onc

e, us

e arro

w ke

ys to

set

the lo

wer li

mit to

50°

OM

RO

NE5

CN

OM

RO

NE5

CNPV SV

OUT

1

Pres

s and

hold

until

the

tempe

ratur

e is d

isplay

ed

OM

RO

NE

5CN

OM

RO

NE

5CNPV SV

OUT

1

Pres

s onc

e, inS

is di

splay

ed

OM

RO

NE

5CN

OM

RO

NE

5CNPV SV

OUT

1

Pres

s onc

e (HY

S ap

pear

s) us

e the

ar

row

keys

to se

t the S

V va

lue by

mo

del (s

ee ch

art)

OM

RO

NE5

CN

OM

RO

NE5

CNPV SV

OUT

1

Pres

s onc

e (iC

Pt ap

pear

s)Us

e arro

w ke

ys to

chan

ge S

V va

lue

from

0 to 2

OM

RO

NE

5CN

OM

RO

NE

5CNPV SV

OUT

1

Pres

s and

hold

(oAP

t app

ears)

Us

e arro

ws ke

ys to

chan

ge S

V va

lue

from

0 to 2

OM

RO

NE

5CNPV SV

OUT

1

Pres

s and

hold

(oAP

t app

ears)

Us

e arro

ws ke

ys to

chan

ge S

V va

lue

from

2 to 0

OM

RO

NE

5CNPV SV

OUT

1

Pres

s onc

e (iC

Pt ap

pear

s)Us

e arro

w ke

ys to

chan

ge S

V va

lue

from

2 to 0

OM

RO

NE5

CN

OM

RO

NE5

CNPV SV

OUT

1

Pres

s and

hold

until

the

tempe

ratur

e disp

lay ap

pear

s

OM

RO

NE

5CNPV SV

OUT

1

Pres

s and

hold

(in-t

appe

ars)

Use a

rrow

keys

to ad

just th

e SV

value

if re

quire

d4 =

“T” t

herm

ocou

ple2 =

“J” t

herm

ocou

ple

OM

RO

NE

5CNPV SV

OUT

1

Pres

s onc

e (d -

U ap

pear

s)Us

e arro

w ke

ys to

togg

le the

SV

units

(F° o

r C°)

OM

RO

NE5

CNPV SV

OUT

1


Appendix S 3000 Repair
13.2 Fuji Temperature Controller Hysteresis (differential) Adjusting
SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SVPV

C1C2

AL1

AL3

AL2

SEL

SEL

SVPV

C1C2

AL1

AL3

AL2

REC

OM

MEN

DED

HYS

TER

ESIS

(DIF

FER

ENTI

AL)

VA

LUES

BY

MO

DEL

E11

00, E

700M

, E22

00, E

3000

, Pur

ehea

t =

10

Arct

ic B

ear X

HD

& H

D m

odel

s =

5

FUJI

PX

R-4

HY

STE

RE

SIS

(DIF

FER

EN

TIA

L) A

DJU

STI

NG

2TA

P ON

CE, T

HE G

REEN

NU

MBER

WILL

BEG

IN F

LASH

ING

X 1

3TA

P TW

ICE,

THE

VAL

UE O

F TH

E GR

EEN

NUMB

ER S

HOUL

D RE

AD Z

ERO

X 2

PRES

S &

HOLD

UNT

IL TH

E NO

RMAL

DIS

PLAY

APP

EARS

4

5PR

ESS

AND

HOLD

, RE

LEAS

E W

HEN

PIS

DIS

PLAY

ED

1PR

ESS

AND

HOLD

, RE

LEAS

E W

HEN

LoC

IS D

ISPL

AYED

8TA

P RE

PEAT

EDLY

UNT

IL TH

E VA

LUE

CO

RRES

POND

S TO

THE

GUI

DE B

ELOW

7TA

P ON

CE, T

HE G

REEN

NUM

BERS

W

ILL B

EGIN

FLA

SHIN

G

6TA

P RE

PEAT

EDLY

UNT

IL HY

S IS

DIS

PLAY

EDPR

ESS

& HO

LD U

NTIL

THE

NORM

AL D

ISPL

AY A

PPEA

RS

9

2TA

P ON

CE, T

HE G

REEN

NU

MBER

WILL

BEG

IN F

LASH

ING

3TA

P TW

ICE,

THE

VAL

UE O

F TH

E GR

EEN

NUMB

ER S

HOUL

D RE

AD T

WO

PRES

S &

HOLD

UNT

IL TH

E NO

RMAL

DIS

PLAY

APP

EARS

41

PRES

S AN

D HO

LD,

RELE

ASE

WHE

N Lo

CIS

DIS

PLAY

ED

SEL

SVPV

C1C2

AL1

AL3

AL2

SVPV

C1C2

AL1

AL3

AL2

SEL

SEL

SVPV

C1C2

AL1

AL3

AL2

X 1

SEL

SVPV

C1C2

AL1

AL3

AL2 X 2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SVPV

C1C2

AL1

AL3

AL2

SEL

X 1


13.3 Fuji Temperature Controller Low Temperature Limit Adjusting
SEL

SVPV

C1C2

AL1

AL3

AL2

SVPV

C1C2

AL1

AL3

AL2

SEL

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPVSVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SVPV

C1C2

AL1

AL3

AL2

SEL

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SVPV

C1C2

AL1

AL3

AL2

SEL

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

LOW

TEM

PER

ATU

RE

LIM

IT V

ALU

ES B

Y M

OD

EL

E110

0, E

700M

, E22

00, S

3000

, E30

00, P

ureh

eat

= 50

Ar

ctic

Bea

r XH

D &

HD

mod

els

= 50

FUJI

PX

R-4

LO

W T

EM

PE

RA

TUR

E L

IMIT

AD

JUS

TIN

G

2TA

P ON

CE, T

HE G

REEN

NU

MBER

WILL

BEG

IN F

LASH

ING

X 1

3TA

P TW

ICE,

THE

VAL

UE O

F TH

E GR

EEN

NUMB

ER S

HOUL

D RE

AD Z

ERO

X 2

PRES

S &

HOLD

UNT

IL TH

E NO

RMAL

DIS

PLAY

APP

EARS

4

SEL

1PR

ESS

AND

HOLD

, RE

LEAS

E W

HEN

LoC

IS D

ISPL

AYED

PRES

S &

HOLD

UNT

IL TH

E NO

RMAL

DIS

PLAY

APP

EARS

9

C1C2

AL1

AL3

AL2

PRES

S &

HOLD

UNT

IL TH

E NO

RMAL

DIS

PLAY

APP

EARS

13

8TA

P RE

PEAT

EDLY

UNT

IL TH

E VA

LUE

CO

RRES

POND

S TO

THE

GUI

DE B

ELOW

7TA

P ON

CE, T

HE G

REEN

NUM

BERS

W

ILL B

EGIN

FLA

SHIN

G

C1C2

AL1

AL3

AL2

X 1

5PR

ESS

AND

HOLD

, RE

LEAS

E W

HEN

P-n

1 IS

DISP

LAYE

DTA

P RE

PEAT

EDLY

UNT

IL SV

-L

IS D

ISPL

AYED

6

11TA

P ON

CE, T

HE G

REEN

NU

MBER

WILL

BEG

IN F

LASH

ING

X 1

12TA

P TW

ICE,

THE

VAL

UE O

F TH

E GR

EEN

NUMB

ER S

HOUL

D RE

AD T

WO

X 2

10PR

ESS

AND

HOLD

, RE

LEAS

E W

HEN

LoC

IS D

ISPL

AYED


13.4 Fuji Temperature Controller High Temperature Limit Adjusting
SEL

SVPV

C1C2

AL1

AL3

AL2

SVPV

C1C2

AL1

AL3

AL2

SEL

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SVPV

C1C2

AL1

AL3

AL2

SEL

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SVPV

C1C2

AL1

AL3

AL2

SEL

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

SEL

SVPV

C1C2

AL1

AL3

AL2

HIG

H T

EMPE

RA

TUR

E LI

MIT

VA

LUES

BY

MO

DEL

E11

00, E

700M

, E22

00, S

3000

, E30

00, P

ureh

eat

= 18

0 Ar

ctic

Bea

r XH

D &

HD

mod

els

= 21

0

FUJI

PX

R-4

HIG

H T

EM

PE

RA

TUR

E L

IMIT

AD

JUS

TIN

G

2TA

P ON

CE, T

HE G

REEN

NU

MBER

WILL

BEG

IN F

LASH

ING

X 1

3TA

P TW

ICE,

THE

VAL

UE O

F TH

E GR

EEN

NUMB

ER S

HOUL

D RE

AD Z

ERO

X 2

PRES

S &

HOLD

UNT

IL TH

E NO

RMAL

DIS

PLAY

APP

EARS

41

PRES

S AN

D HO

LD,

RELE

ASE

WHE

N Lo

C IS

DIS

PLAY

ED

PRES

S &

HOLD

UNT

IL TH

E NO

RMAL

DIS

PLAY

APP

EARS

9

PRES

S &

HOLD

UNT

IL TH

E NO

RMAL

DIS

PLAY

APP

EARS

13

8TA

P RE

PEAT

EDLY

UNT

IL TH

E VA

LUE

CO

RRES

POND

S TO

THE

GUI

DE B

ELOW

C1C2

AL1

AL3

AL2

7TA

P ON

CE, T

HE G

REEN

NUM

BERS

W

ILL B

EGIN

FLA

SHIN

G

X 1

5PR

ESS

AND

HOLD

, RE

LEAS

E W

HEN

P-n

1 IS

DISP

LAYE

DTA

P RE

PEAT

EDLY

UNT

IL SV

-H

IS D

ISPL

AYED

6

11TA

P ON

CE, T

HE G

REEN

NU

MBER

WILL

BEG

IN F

LASH

ING

X 1

12TA

P TW

ICE,

THE

VAL

UE O

F TH

E GR

EEN

NUMB

ER S

HOUL

D RE

AD T

WO

X 2

10PR

ESS

AND

HOLD

, RE

LEAS

E W

HEN

LoC

IS D

ISPL

AYED


13.5 Threadlockers and Sealants
Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Thread-locking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker Neuson Machines.

TYPE( ) = Europe COLOR USAGE

PART NO. –SIZE

Loctite 222Hernon 420Omnifit 1150 (50M)

Purple Low strength, for locking threads smaller than 6 mm (1/4”).Hand tool removable.Temp. range: -54 to 149°C (-65 to 300°F)

73287 - 10 ml


Blue Medium strength, for locking threads larger than 6 mm (1/4”).Hand tool removable.Temp. range: -54 to 149°C (-65 to 300°F)

29311 - .5 ml17380 - 50 ml

Loctite 271/277Hernon 427Omnifit 1550 (220M)

Red High strength, for all threads up to 25 mm (1”).Heat parts before disassembly.Temp. range: -54 to 149°C (-65 to 300°F)

29312 - .5 ml26685 - 10 ml73285 - 50 ml

Loctite 290Hernon 431Omnifit 1710 (230LL)

Green Medium to high strength, for locking preassembled threads and for sealing weld porosity (wicking).Gaps up to 0.13 mm (0.005”)Temp. range: -54 to 149°C (-65 to 300°F)

28824 - .5 ml25316 - 10 ml

Loctite 609Hernon 822Omnifit 1730 (230L)

Green Medium strength retaining compound for slip or press fit of shafts, bearings, gears, pulleys, etc.Gaps up to 0.13 mm (0.005”) Temp. range: -54 to 149°C (-65 to 300°F)

29314 - .5 ml


Brown Hydraulic sealantTemp. range: -54 to 149°C (-65 to 300°F)

79356 - 50 ml

Loctite 592Hernon 920Omnifit 790

White Pipe sealant with Teflon for moderate pressures.Temp. range: -54 to 149°C (-65 to 300°F)

26695 - 6 ml73289 - 50 ml

Loctite 515Hernon 910Omnifit 10

Purple Form-in-place gasket for flexible joints.Fills gaps up to 1.3 mm (0.05”)Temp. range: -54 to 149°C (-65 to 300°F)

70735 - 50 ml


Threadlockers and Sealants (continued)
Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Thread-locking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container. The sealants listed are recommended for use on Wacker Neuson Machines.

TYPE( ) = Europe COLOR USAGE

PART NO. –SIZE

Loctite 496Hernon 110Omnifit Sicomet 7000

Clear Instant adhesive for bonding rubber, metal and plastics; general purpose.For gaps up to 0.15 mm (0.006”)Read caution instructions before using.Temp. range: -54 to 82°C (-65 to 180°F)

52676 - 1oz.

Loctite Primer THernon Primer 10Omnifit VC Activator

AerosolSpray

Fast curing primer for threadlocking, retaining and sealing compounds. Must be used with stainless steel hardware. Recommended for use with gasket sealants.

2006124-6 oz.


13.6 Torque Values
Metric Fasteners (DIN)

TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE

Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch

M3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 –

M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 –

M5 6.0 *53 8.5 6 10 7 8 5/16 4 –

M6 10 7 14 10 17 13 10 – 5 –

M8 25 18 35 26 41 30 13 1/2 6 –

M10 49 36 69 51 83 61 17 11/16 8 –

M12 86 63 120 88 145 107 19 3/4 10 –

M14 135 99 190 140 230 169 22 7/8 12 –

M16 210 155 295 217 355 262 24 15/16 14 –

M18 290 214 405 298 485 357 27 1-1/16 14 –

M20 410 302 580 427 690 508 30 1-1/4 17 –

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm

8.8 10.9 12.9


Torque Values (continued)
Inch Fasteners (SAE)

Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch

No.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32

No.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64

No.8 2.5 *22 3.5 *31 4.7 *42 9 11/32 – 9/64

No.10 3.6 *32 5.1 *45 6.8 *60 – 3/8 – 5/32

1/4 8.1 6 12 9 16 12 – 7/16 – 3/32

5/16 18 13 26 19 33 24 13 1/2 – 1/4

3/8 31 23 45 33 58 43 – 9/16 – 5/16

7/16 50 37 71 52 94 69 16 5/8 – 3/8

1/2 77 57 109 80 142 105 19 3/4 – 3/8

9/16 111 82 156 115 214 158 – 13/16 – –

5/8 152 112 216 159 265 195 24 15/16 – 1/2

3/4 271 200 383 282 479 353 – 1-1/8 – 5/8

1 ft.lb. = 1.357 Nm * = in.lb. 1 inch = 25.4 mm


Wacker Neuson SE · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21

Documents

S 3000products.wackerneuson.com/manuals/Repair/0178388enRep.pdf · S 3000 REPAIR MANUAL 0178388en 002 0209 0178388 EN. S 3000 Repair Foreword ... Use the separate Parts Book supplied