MAC 750F Flameless Air Heater
Contents
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3. 000204 The heater is designed to operate with diesel fuel Fuel tank is 160 gal 605 67L with 152 gal 575L usable IMPORTANT NOTE Comply with all laws regulating the storage and handling of fuels Follow these guidelines Use only ultra low sulfur diesel fuel e When temperatures are at or below freezing use No 1D diesel fuel e When temperatures are above freezing use No 2D diesel fuel n some areas of the country Climatized Fuel a mixture of 1D and 2D may also be used Hydraulic Oil Hydraulic Fluid Injection High pressure high temperature hydraulic fluid can pierce skin and cause severe burns Do not check for leaks with hands Seek immediate medical attention in case of accident Failure to protect body accordingly will result in death or serious injury 000239 Type Exxon Mobile DTE 10 ISO VG 68 hydraulic oil System capacity 25 gal 94 64 L Trailer Towing Guidelines Trailer must be securely coupled to the hitch and chains correctly attached Uncoupled or unchained towing could result in death or serious injury 000233 Property or Equipment Damage Tighten wheel lug nuts after first 50 miles to factory specifications Failure to do so could result in death serious injury propery or equipment damage 000235 Owner s Manual for Flameless Air Heater Driving a vehicle with a trailer in tow is vastly different than driving the same vehicle without a trailer in t
4. Unit damage Do not stop engine before heating unit is cooled Doing so could result in unit damage 000240a 2 When the control screen indicates it is safe to turn off the engine turn the ignition key to OFF 11 Operation This page intentionally left blank 12 Owner s Manual for Flameless Air Heater Section 4 Maintenance NOTE Normal maintenance service and replacement of parts is the responsibility of the owner and as such are not considered defects in materials or workmanship within the terms of the warranty It is strongly recommended that equipment be periodically checked by an IASD Maintenance Tasks Daily checks must be performed when unit is operated continuously for extended periods of time Daily checks and routine monthly checks can be performed by an authorized operator Daily Walk Around Inspection Look for conditions that could hinder performance or safety such as but not limited to oil coolant fuel leakage blocked vents loose or missing hardware and electrical connections Check for foreign matter blocking the vents and on top of unit Visually inspect outer cover for significant damage beyond scuffs and small nicks Visually inspect for wire abrasion Visually inspect the fan belt for cracks fraying and stretching Verify belt is properly seated in the pulley grooves Every 750 hours it is recommended that the belt be removed and checked for wear While belt is removed inspe
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6. If necessary replenish with a commercially available electrolyte such as distilled water Operation Engine and Heater Startup 1 Close all doors that access the unit s interior IMPORTANT NOTE All doors on the unit must be closed during operation 2 Turn ignition key to ON The screen displays Engine Preheat Figure 3 1 Engine Preheat 0 RPM 0 FUEL LEVEL 0 0 VOLTS 0 0 ENG HRS 001580 1 800 272 4604 www macflameless com Figure 3 1 Engine Preheat 3 When screen displays Start Engine Figure 3 2 turn ignition key to START 10 Equipment Damage Do not continuously crank engine for more than ten seconds Doing so will lead to overdischarge of batteries and starter seizure 000230 1 800 272 4604 www macflameless com 001584 Figure 3 2 Start Engine 4 The screen displays Engine Warming Figure 3 3 Engine Warming ON Please Wait 1 800 272 4604 www macflameless com 001585 Figure 3 3 Engine Warming 5 When the coolant temperature reaches 140 F 60 C engine warming is complete and the heater automatically begins warming up The screen displays Heater is warming up Please wait Figure 3 4 32 Fuel Tem pF 0 RPM 0 FUEL LEVEL 0 0 PSI AIR PRESS 0 0 VOI 1 800 272 4604 0 0 ENG HRS www macflameless com 001581 Figure 3 4 Heater Warming 6 When the heater is warm heat begins blowing from ducts and screen displays Heater on Pr
7. marks on the dipstick Hydraulic Oil Check 1 On the hydraulic fluid reservoir tank is a gauge showing hydraulic oil level Verify level is between MIN and MAX Owner s Manual for Flameless Air Heater Operation Engine Coolant Check 9 WEG 58 8 Risk of burns Do not open coolant system until engine has completely cooled Doing so could result in serious injury 000154 yit 1 Remove radiator fill cap 2 Check coolant level and degrees of fouling Coolant level should be approximately 10 mm below the radiator core top 3 Install radiator cap securely Battery Check oli Electrical shock Disconnect battery ground terminal before working on battery or battery wires Failure to do so could result in death or serious injury 000164 Risk of burn Do no open or mutilate batteries Batteries contain electrolyte solution which can cause burns and blindness If electrolyte contacts skin or eyes flush with water and seek immediate medical attention 000163a Explosion Batteries emit explosive gases while charging Keep fire and spark away Wear protective gear when working with batteries Failure to do so could result in death or serious injury TTT 000137a NALE make battery connections in reverse Doing so will result in equipment damage 000167 1 Verify battery cable connections are not loose or corroded 2 Verify battery electrolyte level is sufficient
8. White Needs more warm up time Conduct warm up operation Too much engine oil Correct oil level Engine control system fails Contact Generac Technical Injection pump failure Service Fuel system failure Long time idling more than two hours Keep stopping the equipment and press throttle pedal Exhaust smoke is Black Excessive speed Verify engine RPM Check AVR adjustment Injection pump failure Contact Generac Technical Service Air cleaner is clogged Clean or change element Intercooler is clogged Contact Generac Technical Fuel system failure Service Exhaust system is clogged Engine Overheats No coolant Add coolant Front of radiator is clogged with dust Clean with soft brush Sub tank cap is not tightened Tighten or replace sub tank cap Coolant is fouled Clean inside of radiator and change coolant Oil is in coolant Contact Generac Technical Service Thermostat failure Change thermostat Oil Pressure Does Not Rise Engine oil viscosity is incorrect Change with oil of correct viscosity Engine oil level is not sufficient Replenish Engine failure Contact Generac Technical Meter lamp or switch failure Service Engine Has No Power Air cleaner is clogged Clean element Pre fuel filter is clogged Fuel filter is clogged Remove water and ch
9. or concerns The owner is responsible for proper maintenance and safe use of the equipment SAVE THESE INSTRUCTIONS for future reference This manual contains important instructions for the heater that should be followed during installation operation and maintenance of the heater and batteries ALWAYS supply this manual to any individual that will use this machine THE INFORMATION CONTAINED HEREIN WAS BASED ON MACHINES IN PRODUCTION AT THE TIME OF PUBLICATION GENERAC RESERVES THE RIGHT TO MODIFY THIS MANUAL AT ANY TIME Safety Rules The manufacturer cannot anticipate every possible circumstance that might involve a hazard The warnings in this manual and on tags and decals affixed to the unit are therefore not all inclusive If using a procedure work method or operating technique that the manufacturer does not specifically recommend verify that it is safe for others Also make sure the procedure work method or operating technique utilized does not render the equipment unsafe Throughout this publication and on tags and decals affixed to the unit DANGER WARNING CAUTION and NOTE blocks are used to alert personnel to special instructions about a particular operation that may be hazardous if performed incorrectly or carelessly Observe them carefully Their definitions are as follows Owner s Manual for Flameless Air Heater LADANGER Indicates a hazardous situation which if not avoided will result in death or ser
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11. COSITY GRADE AMBIENT TEMPERATURE Single grade SAE 20 20W SAE 40 SAE 10W SAE 30 Ambient 25 C 20 C 15 C oC 15 C 25 30 C Temperature 13 F 4 F 5 F 32 F 59 F TTF 86 F SAE 10W 30 Multi grade SAE 15W 40 20W 40 SAE 5W 20 001577 NOTE For temperatures below 13 F use SAE 5W 30 For more information see the engine manual Coolant Recommendation ADANGER A Risk of poisoning Do not use mouth to siphon coolant Doing so will result in death or serious injury 000149 Where the atmospheric temperature falls below freezing the cooling system should be drained after engine operation To eliminate the need for repeated draining and refilling the use of a 50 50 Ethylene glycol base antifreeze water mix is recommended Never exceed a 60 40 antifreeze water mix 3 13 31 58 Freezing Point F C 16 25 35 50 Coolant Volume 30 40 50 60 Water Volume 70 60 50 40 Coolant capacity is 6 3 qts 6L For more information see the engine manual Fuel System ADANGER Explosion and Fire Fuel and vapors are extremely flammable and explosive Keep fire and spark away Failure to do so will result in death or serious injury 000168 VONT Explosion and Fire Do not overfill fuel tank Overfilling may cause fuel to leak and ignite or explode resulting in death or serious injury
12. ESP ERAT 7 Monitoring Diagnostic and Protective Features 8 Section 3 Operation Before Starting Engine eene 9 Pre start Checklist sssee 9 Engine Oil Check nennen 9 Hydraulic Oil Check 9 Engine Coolant Check saesssssessssrsssssrnneersernesisnnnnneenns 9 Battery Check esent 9 Engine and Heater Startup 10 Adjusting Heater Output eeeeeeee 11 AUTO Mode rere ter erra terae 11 MANUAL Mode eee 11 Heater and Engine Shutdown 11 Owner s Manual for Flameless Air Heater Section 4 Maintenance Maintenance Tasks eeeeeneeenen nnn 13 Daily Walk Around Inspection ssss 13 Check Engine Oil Level esseeees 13 Drain the Oil 15 ett tec 13 Adding Coolant sene 14 Maintenance Schedule enne 14 Engine Maintenance Schedule 15 Battery Inspection eeeeeeennn 16 Battery Installation and Replacement 17 Other Maintenance Checks eene 17 Section 5 Troubleshooting General Troubleshooting Guide 19 Digital Controller Status Messages 21 Section 6 Installation Diagrams and Se
13. GENERAC MAC MAC 750F Flameless Air Heater Owner s Manual MODEL NUMBER SERIAL NUMBER DATE PURCHASED Register your Generac Mobile Product at WWW GENERACMOBILE COM 800 926 9768 SAVE THIS MANUAL FOR FUTURE REFERENCE California Proposition 65 Engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm 000004 California Proposition 65 This product contains or emits chemicals known to the state of California to cause cancer birth defects and other reproductive harm 000005 Owner s Manual for Flameless Air Heater Table of Contents Section 1 Introduction and Safety dee tee d NEE 1 Safety Rules ener rne 1 General Hazards eese 2 Explosion and Fire Hazards 2 Trailer Hazards iier hne 2 Battery Hazards eese 3 Section 2 General Information Component Locations REENEN 5 Engine Oil Recommendations eeee 6 Coolant Recommendation NEG 6 Fuel System ener creer ENEE eene e iaaa 6 Hydraulic Oil irr 6 Trailer Towing Guidelines ees 6 Wheel Chock Guidelines sssssssssss 7 Informational Decals eec 7 Controller ETE erneut nE n nr R
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15. ameless Air Heater 26 Installation Diagrams and Service Log Service Log OIL GRADE BRAND COOLANT MIXTURE BRAND Date Hours to oitever oan Date Hours to i ppap oo Service Level Service Level Owner s Manual for Flameless Air Heater 27 GENERAC MAC Part No 3022147 Rev A 10 29 15 Printed in USA Generac Mobile Products Generac Mobile Products All rights reserved 215 Power Drive Specifications are subject to change without notice Berlin WI 54923 2420 No reproduction allowed in any form without prior written 800 926 9768 consent from Generac Mobile Products generacmobile com
16. ange element Strainer is clogged Engine control system failure Engine failure Contact Generac Technical Exhaust system is clogged Service Fuel system failure Type of fuel is incorrect Electromagnetic type fuel pump failure Overheat shutdown condition 20 Access doors are open Close all access doors Air outlets are not open Open the air outlets and verify there are no obstructions or kinks in the ducting Front radiator or rear oil cooler are full of debris Engine RPM is set too high based on ambient temperature Clean the machine Lower the engine RPM Faulty temperature sensor Check air outlet sensor operation Blower fan not operating correctly Remove ducting check blower fan operation Owner s Manual for Flameless Air Heater Troubleshooting Problem Cause Solution ture too low Incorrect heater setting target tempera Adjust heater output Access doors are open Close all access doors No low heat condition Low HTF hydraulic oil level Check level on tank sight glass adjust as needed Inspect HTF hoses for leaks or loose fittings Check fluid for foaming HTF hydraulic oil filters clogged Check restriction gauges replace HTF filters Ducting too long for ambient conditions Move unit closer to heat recipient if possible HTF pump drive sheared Contact Generac tec
17. ct pulleys and bearing Rotate and feel for hard turning or unusual sounds Coolant should be checked daily Check electrical connectors battery and ground points Look for loose or missing hardware Check all flexible rubber hoses for deterioration Check hydraulic hoses for signs of wear Verify hoses are not crushed kinked or twisted Verify there are no cracks or corrosion Check Engine Oil Level Engine damage Verify proper type and quantity of engine oil prior to starting engine Failure to do so could result in engine damage 000135 NOTE If engine was running wait at least ten minutes before proceeding 1 Remove dipstick and wipe it dry with a clean lint free cloth 2 Slowly insert the clean dipstick into the tube Verify the dipstick is fully seated in the dipstick tube Owner s Manual for Flameless Air Heater Maintenance 3 After ten seconds remove the dipstick and look at the oil level on both sides The lower of the two readings will be the correct oil level measurement 4 Add oil if necessary to adjust the level After adding or changing the oil the engine should run for one minute before checking the oil level Wait ten minutes to allow the engine to cool and oil to fully drain into the oil pan Typical causes of inaccurate oil level readings Reading the high level of the dipstick Reading the dipstick before the oil fully drains into the oil pan Inserting a
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20. diator slowly with coolant until it comes up to the filler neck 4 Operate engine approximately five minutes at a low idle speed to bleed the air in the coolant circuit NOTE Coolant level will drop 5 Stop the engine and once cooled replenish with coolant 14 Maintenance Schedule Periodic inspection service and maintenance of this unit is critical to ensure reliable operation The following is the manufacturer s recommended maintenance schedule The maintenance items will need to be performed more frequently if the heater is used in severe applications such as very high or very low ambient conditions or extremely dirty dusty environments Use the heater hour meter or calendar time whichever occurs first from the previous maintenance interval to determine the next required maintenance interval Note that some checks are based on hours of operation Follow all applicable safety alerts found in this manual or engine service manual before performing any maintenance checks or service This maintenance schedule reflects the minimum tasks that need to be accomplished to verify the heater remains operational Some of the tasks can be performed by an authorized operator and others must be performed by an IASD NOTE An authorized operator is one who has been trained by a IASD in proper operation and inspection of this unit Owner s Manual for Flameless Air Heater Engine Maintenance Schedule Maintenance e Chec
21. e material accumulation underneath Failure to do so could result in death or serious injury 000147 O AWANNG Do not operate this unit while transporting Doing so could result in death or serious injury 000231 Ql Hearing Loss Hearing protection is recommended when using this machine Failure to wear hearing protection could result in permanant hearing loss 000107 Moving Parts Keep clothing hair and appendages away from moving parts Failure to do so could result in death or serious injury 000111 Hot Surfaces When operating machine do not touch hot surfaces Keep machine away from combustibles during use Hot surfaces could result in severe burns or fire bm p 000108 CAUTIONS Equipment or property damage Do not block air intake or restrict proper air flow Doing so could result in unsafe operation or damage Unit damage Do not stop engine before heating unit is cooled Doing so could result in unit damage 000240a Trailer Hazards Trailer must be securely coupled to the hitch and chains correctly attached Uncoupled or unchained towing could result in death or serious injury 000233 20 AWARNNG Verify unit is properly secured with wheel chocks and on level ground Failure to do so could result in death or serious injury 000234 Property or Equipment Damage Tighten wheel lug nuts after first 50 miles to factory specifications Fail
22. echnical Service Restricted air flow Check replace air filter LCD Display panel shows engine failure Strainer is clogged Pre heating device failure Contact Generac Technical Service Engine Will Not Crank Electric Start Dead battery Replace battery Battery terminal is disconnected loose or corroded Starter ground terminal is disconnected loose or corroded Replace corroded part and tighten securely Engine oil viscosity is too high Change with oil of correct viscosity Starter or electrical system failure Contact Generac Technical Service Engine Starts But Stops Shortly Thereafter Idling is too low Adjust by idling control equipment on the machine If adjustment is not possible contact ISUZU dealer Fuel filter is clogged Remove water and change ele ment Pre fuel filter is clogged Air cleaner is clogged Clean or change element Engine control system failure Injection pump failure Strainer is clogged Electromagnetic type fuel pump failure Engine Running is Unstable Fuel system failure Contact Generac Technical Service Water or air is in fuel system Bleed air or remove water Engine control system failure Contact Generac Technical Service Owner s Manual for Flameless Air Heater Troubleshooting Problem Cause Solution Exhaust Smoke is
23. eck alternator drive belt tension and replace if necessary Every 1500 Hours After 1500 Hours All hours based checks and maintenance should now be performed every 250 hours The following maintenance items should be performed annually regardless of operation hours Hydraulic breather separator Carbon Monoxide CO test at outlet air duct by trained service technician Blower fan hardware for condition and tightness Annual Change Owner s Manual for Flameless Air Heater 15 Maintenance NOTE For items marked consult equipment supplier NOTE All service and maintenance or repairs are recommended to be completed by an IASD to maintain the warranty status of a unit You cannot be denied emissions warranty coverage solely based on failure to complete recommended service maintenance NOTE For additional maintenance information see engine manual Battery Inspection Explosion Batteries emit explosive gases while charging Keep fire and spark away Wear protective gear when working with batteries Failure to do so could result in death or serious injury JY 9001372 Explosion Do not dispose of batteries in a fire Batteries are explosive Electrolyte solution can cause burns and blindness If electrolyte contacts skin or eyes flush with water and seek immediate medical attention 000162 Lem Wee Risk of burn Do no open or mutilate batteries Batteries contain el
24. ectrolyte solution which can cause burns and blindness If electrolyte contacts skin or eyes flush with water and seek immediate medical attention 000163a Accidental Start up Disconnect the negative battery cable then the positive battery cable when working on unit Failure to do so could result in death or serious injury 000130 Vision Loss Eye protection is required to avoid gt spray from spark plug hole when cranking engine Failure to do so could result in vision loss 000181 Environmental Hazard Always recycle batteries at an official recycling center in accordance with all local laws and regulations Failure to do so could result in environmental damage death or serious injury 000228 NOTE Remove five amp controller fuse from control panel 16 An authorized operator should inspect the engine battery monthly At this time the battery fluid level should be checked using a load tester and distilled water added if needed Battery cables and connections should also be inspected for cleanliness and corrosion Once every six months an IASD should inspect the battery system At this time the battery condition and state of charge should be checked using a load test battery The battery should be recharged or replaced as required Battery service is to be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away Obse
25. erating condition data on outlet temperature engine RPMs and fuel level For more information refer to the controller wiring diagrams Owner s Manual for Flameless Air Heater Section 3 Operation Before Starting Engine Pre start Checklist Hot Surfaces When operating machine do not HD Touch hot surfaces Keep machine away from combustibles during use Hot surfaces could result in severe burns or fire 000108 e Remove all flammable materials and fire hazards within 5 feet of heater Keep heater a minimum of 5 feet from structures or barricades Verify unit is not leaking fluids check inside and outside the unit for leaking fuel engine oil HTF hydraulic oil and engine coolant e Verify the following are clear of debris and obstructions Engine air intake Engine exhaust stack Outlets and fan intakes Verify air duct hose is securely fastened to outlet duct assembly Check fuel engine oil and engine coolant levels Verify unit is properly secure with jacks deployed if applicable wheels chocked and level e Check alternator drive belt for tension and wear Engine Oil Check Engine damage Verify proper type and quantity of engine oil prior to starting engine Failure to do so could result in engine damage 000135 1 Remove dipstick from crankcase and wipe it clean 2 Insert dipstick fully and remove slowly 3 Oil level must be between the FULL and ADD
26. ess Off to stop the heater Figure 3 5 1 800 272 4604 www macflameless com 001586 Figure 3 5 Heater On Owner s Manual for Flameless Air Heater Adjusting Heater Output The heater has two modes AUTO and MANUAL The current mode displays at the top of the controller screen AUTO Mode In AUTO mode output temperature is manually set as follows To increase output temperature press Figure 3 6 item A To decrease output temperature press Figure 3 6 item B 001578 Figure 3 6 AUTO mode MANUAL Mode In MANUAL mode heater output can be set to minimum fan or maximum fan as follows For minimum fan press MIN FAN Figure 3 7 item A For maximum fan press MAX FAN Figure 3 7 item B Press On to start heater Een or Shut off engine 1 800 272 4604 www macllameless com 001579 Figure 3 7 MANUAL mode Owner s Manual for Flameless Air Heater Operation Heater and Engine Shutdown 1 Press OFF to stop the heater Figure 3 7 item C The screen displays Heater is cooling down Please wait Figure 3 8 1 800 272 4604 O www macflameless com 0 0 ENG HRS 001582 Figure 3 8 Heater Cooling NOTE During cool down the ON button is disabled When cool down is complete the screen displays as shown in Figure 3 9 Press On to start heater or Shut off engine 1 800 272 4604 www macflameless com 001583 Figure 3 9 Cool down Complete
27. hnical service Digital Controller Status Messages Message Cause Engine Warming Please Wait Engine coolant temperature lt 140 Engine Preheat Wait approximately ten seconds after heater power up Engine is not ready Check RPMs Fuel Level or Wait to Start Engine RPMs lt 500 Fuel level lt 10 Wait to Start signal Low Fuel Warning Fuel level lt 20 Fuel level notification appears on screen Fuel level lt 16 Fuel level notification appears on screen Heat fan load reduced to 50 Fuel level lt 12 Fuel level notification appears on screen Open heat circuit and close scroll fan circuit Drop engine to idle Fuel level 896 Fuel level notification appears on screen Engine shuts down Check heater settings or connections then Reset on the Machine Overview IFM controller detected a short or break in a sender Heater is cooling down Please wait IFM controller detects heater is in cool down ON button dis abled Engine is going to shutdown Fuel level lt 12 for 3 hours and 15 minutes Engine Fault Shutdown Low engine oil pressure High engine coolant temperature Engine overspeed Owner s Manual for Flameless Air Heater 21 Troubleshooting Message Cause Heater Shutdown due to temperature pressure or level out of range High hydraulic temperature Low hydraulic press
28. hocks Owner s Manual for Flameless Air Heater General Information Informational Decals Location Decal Description Tire and loading information On back of Manufacturer s label provides VIN model date of manufacture GVWR vehicle class and tire and rim size Emissions label right side door Inside unit right Serial amp Model VIN MAC phone side riveted to blower housing Metal blue silver color Tire and loading information Front of trailer Decal showing VIN model date near jack of manufacture GVWR and tire and rim size Controller For troubleshooting see Digital Controller Status Messages 001576 Figure 2 2 Controller Button Position Manual Mode Auto Mode A increase heat Increase temperature setting B inereasetan Decrease temperature setting C Overview Analog gauge screen D Main menu E Heater on off F Next screen G Popup Softkeys General Information Monitoring Diagnostic and Protective Features The unit mechanical and electrical systems are connected to various sensors that monitor unit status If conditions occur outside of predetermined manufacturing parameters the controller will automatically stop the machine and display fault information The controller can also display a variety of critical alerts diagnostics and recommendations The controller provides a variety of real time current op
29. ious injury 000001 00 AWANNG Indicates a hazardous situation which if not avoided could result in death or serious injury 000002 ACAUTON Indicates a hazardous situation which if not avoided could result in minor or moderate injury 000003 NOTE Notes contain additional information important to a procedure and will be found within the regular text of this manual These safety warnings cannot eliminate the hazards that they indicate Common sense and strict compliance with the special instructions while performing the action or service are essential to preventing accidents Introduction and Safety General Hazards Asphyxiation Running engines produce carbon monoxide a colorless odorless poisonous gas Carbon monoxide if not avoided will result in death or serious injury 000103 Explosion and Fire Hazards VONT Explosion and Fire Fuel and vapors are extremely flammable and explosive Add fuel in a well ventilated area Keep fire and spark away Failure to do so will result in death or serious injury 000105 x Hydraulic Fluid Injection High pressure high temperature hydraulic fluid can pierce skin and cause severe burns Do not check for leaks with hands Seek immediate medical attention in case of accident Failure to protect body accordingly will result in death or serious injury 000239 Risk of Fire Unit must be positioned in a manner that prevents combustibl
30. k engine oil level Inspect engine for fuel oil and coolant leaks Check oil pressure gauge registration Check oil pressure warning lamp Drain water in fuel filter Check coolant for abnormal color Check coolant level Check coolant temperature gauge Check radiator filler cap fitting condition Check alternator drive belt tension and replace if necessary Inspect air cooler for water leaks Check Engine Malfunction Indicator Lamp and LCD Display Panel Check electrolyte level Clean battery Check battery charge condition Ammeter registration Charge warning lamp Daily Check preheating condition Check engine starting condition Check exhaust smoke condition Every 250 H Replace fuel filter element ours Replace engine oil and oil filter element Every 500 Replace fuel filter element Hours Replace engine air filter Check alternator drive belt tension and replace if necessary Every 750 H Replace fuel filter element ours Replace engine oil and oil filter element Replace fuel filter element Change hydraulic fluid Every 1000 Replace hydraulic filters Hours Check alternator drive belt tension and replace if necessary Check and clean the starter and alternator Check cylinder compression pressure Check valve clearance Every 1250 Replace fuel filter element Hours Replace engine oil and oil filter element Replace fuel filter element Ch
31. l result in equipment damage 000167 1 Connect battery cable from starter contactor to positive POS or battery post 2 Connect black battery cable to negative NEG or battery post 3 Referto Starting the Engine Other Maintenance Checks The following inspections should be performed by an authorized service technician or a properly trained authorized operator These maintenance items require a high level of experience and skill to evaluate and correct Inspect engine accessory drive belts Inspect hoses and connections Inspect fuel supply system Inspect exhaust system Inspect exhaust pipe sleeve Owner s Manual for Flameless Air Heater Maintenance Maintenance This page intentionally left blank 18 Owner s Manual for Flameless Air Heater Section 5 Troubleshooting General Troubleshooting Guide Troubleshooting Problem Cause Solution Engine Cranks But Will Not Start No fuel Verify there is no fuel leakage and replenish Low oil level Replenish oil to full Emergency shutdown switch is ON Turn emergency shutdown switch OFF Air in fuel system Bleed air Fuel filter is clogged Remove water and change ele ment Fuel is frozen Warm fuel pipes with hot water or wait until ambient temperature rises Injection pump fails Electromagnetic type fuel pump failure Engine control system failure Contact Generac T
32. lameless Air Heater Introduction and Safety Introduction and Safety This page intentionally left blank 4 Owner s Manual for Flameless Air Heater General Information Section 2 General Information Component Locations 001574 Left Side Right Side Figure 2 1 Features and Controls Table 1 Heater Components Engine radiator H Controller Breakaway battery for trailer brakes Manual compartment Diesel engine J Diesel engine turbo charger Hydraulic fluid filters K Diesel engine oil dipstick Hydraulic fluid fill L Engine fuel filters Hydraulic fluid reservoir tank M Automatic positive air shutdown Hydraulic fluid breather separator Om mm Do DW gt Owner s Manual for Flameless Air Heater 5 General Information Engine Oil Recommendations Genuine Generac parts are recommended for all maintenance items Generac oil kits include both the oil filter and air filter and can be obtained through any IASD All Generac oil kits meet minimum American Petroleum Institute API Service Class CJ 4 SM Select the appropriate viscosity oil grade according to the expected operating temperature Synthetic oil also can be used in the appropriate weight as standard once the engine has been broken in Once synthetic oil is used it should be used for the life of the unit It is not recommended to go back to a mineral oil Do not use special additives Engine oil capacity including filter is 15 85qt 15L ENGINE OIL VIS
33. n3a d 010 HO9SsLn3ad 9 1M0d S AE EHE ORITUR L668 00 00 Hei f OSbAd 00 00 70Z9 00 00 AHA NNN a cola an L6v8 00 00 AHdSNN wu En MAIN NOLXISNI JAM 9906 00 00 Hdsnn MAA NOLLYASNI 38IM MOLONNOO SSasNd 110 ECCO SOON REN MOLONNOO dfOld OVW Mei o c e MIA NOILN3SNI IAIM ULL S g ANNOG AHO dNXld 9v NYJ SS3Md 110 FANNO AHO S400 90 Z8 AHAYNW XZ H V olay Vi NA e 00 70 8 AHdHnh MIIA NOILYISNI IHM CAE Y AGIA NOLYISNI JAIM d g s ag gt f 8 S 88 ova re L om ee L N 9 9NI 9 ZNI TETE 00 00 Hun S ON 318V9 Noma ey S ON vy ano Y v ou H CO g GNI uw g LNI a ca i h PNI 8 cv 8 ecv 4 H ONI Fs 88 EES EE 8 z iv L S 88 m Je ous T vav es o OY SI v Lo zli 8 ps zl zl 9 m T3A31 10 V BIER BO ana 110 V dZM HOSLNIA d M HOSLNIA dZM Hosinaa dZ v010 Hos1naq d vOlLG HOSINSG dz v010 Hos1n3q 86v8 00 00 Halt 9698 00 00 Hale 8698 00 00 AHdMQW L6v8 00 00 A Hadas L6Y8 00 00 AHAI NW o 9 o 9 L6v8 00 00 Heli MIA NOILS3SNI IHM MJA NOILNSSNI Zu t USI MIA NOILN3SNI IAM o MOLONNOO T3A31 110 MOIONNOO dW3l NIV g x NOLONNOO dl 0 8000 TSNWd JHL 4O YYY JHL NO OO 8 5 Z 3sn4 NY NMOHS SV SHOIO3NNOO T38v1WN AVEVO Q3G TSIHS pa HONI Yad LSIML 3NO WAONWINIW S3SIM Q31SIML s ASIMYSHLO Ode SSFINN SLIHM VO 8L 38 OL c 133HS NO S3MIM TIV 4 SJLON Owner s Manual for Flameless Air Heater 24 Installation Diagrams and Service Log
34. nd removing the dipstick too quickly The dipstick is not fully seated in the dipstick tube Drain the Oil 9 MwaNNG 5 5 Ain Risk of burns Allow engine to cool before draining oil or coolant Failure to do so could result in death or serious injury 000139 20 AWANNG Potential of cancer Prolonged or repeated contact with used motor oil has been shown to cause cancer in laboratory animals Thoroughly wash exposed areas with soap and water 0001272 1 Place container under drain port or connect hose or piping to drain port leading to container Remove plug from oil drain Open drain valve See engine manual for oil filter information Close drain valve Remove hose or piping if applicable Replace plug in drain port on sub base Dn a a S mwN Maintenance Adding Coolant ADANGER AD Risk of poisoning Do not use mouth to siphon coolant Doing so will result in death or serious injury 000149 Risk of burns Do not open coolant system until engine has completely cooled Doing so could result in serious injury NSH feat as aaa 000154 Do not use any chromate base rust inhibitor with propylene glycol base antifreeze boosters or additives Doing so will cause overheating 000165 If coolant level is below the filler neck coolant needs to be added see Coolant Recommendation 1 Verify engine is stopped and cooled 2 Remove radiator cap 3 Fill ra
35. ow Consider the following e t takes longer to get up to speed More room is needed to turn and pass More distance is needed to stop The driver is responsible for keeping the vehicle and trailer in control Before towing verify the following 1 The coupling safety chains safety brake tires wheels and lights are in working order 2 The breakaway battery is fully charged 3 Wheel lug nuts are tightened to 85 95 ft lbs 115 129 Nm 4 Brake controller engages the trailer brakes before the tow vehicle brakes While towing make regular stops to verify the following Coupler is secured to the hitch and locked Electrical connections are made Appropriate slack in the safety chains Appropriate slack in the breakaway switch pull pin cable 5 Tires are inflated to proper air pressure and no damage or unusual wear to tread or sidewalls 6 Trailer and doors are secured and latched ME EE Wheel Chock Guidelines Verify unit is properly secured with wheel chocks and on level ground Failure to do so could result in death or serious injury 000234 Select wheel chock according to equipment type and size Always use in pairs and on firm surfaces Chock in direction of grade Chock both sides of wheel if direction of grade is unknown e Use wheel chock only after parking brake is applied and tested Center chocks squarely against tread of each wheel Do not drive over wheel c
36. rve the following precautions when working on batteries Remove watches rings or other metal objects Use tools with insulated handles Wear rubber gloves and boots Do not lay tools or metal parts on top of battery Disconnect charging source prior to connecting or disconnecting battery terminals NOTE Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbonate of soda baking soda to one gallon four liters of water The bicarbonate of soda solution is to be added until the evi dence of reaction foaming has ceased The resulting liquid is to be flushed with water Discharge static electricity before touching battery by first touching a grounded metal surface Owner s Manual for Flameless Air Heater Battery Installation and Replacement When required the battery must be replaced with one of equivalent size voltage and CCA cold crank amp capacity Minimum CCA for this unit is 2200 2 pairs of 2 1100 CCA 12 volt batteries in series to give 1100 Amps at 24 volts connected in parallel to provide 2200 CCA at 24 volts Contact the local IASD for correct battery size A new battery must be filled with the proper electrolyte and be fully charged before install Battery cables are connected to the unit at the factory Connect cables to battery posts as follows WE make battery connections in reverse Doing so wil
37. rvice Log Engine Harness 1 of 3 eene 23 Engine Harness 2 of 3 eene 24 Engine Harness 3 of 3 eene 25 Trailer Wiring Harness eene 26 Service Log 5er enr deer rrr 27 I This page intentionally left blank Owner s Manual for Flameless Air Heater Introduction and Safety Section 1 Introduction and Safety Introduction Thank you for purchasing a Generac Mobile Product This unit has been designed to provide high performance efficient operation and years of quality use when maintained properly The MAC 750F flameless air heater is designed and built for sustained reliable heat production in industrial operating conditions and environments The MAC 750F is built to withstand frequent handling under these conditions The unit is mounted on a trailer that has forklift access and chain attach points on both sides The fully enclosed design protects the operating components allowing all weather storage and operations LU Consult Manual Read and understand manual completely before using product Failure to completely understand manual and product could result in death or serious InjurY o 094002 If any section of the manual is not understood contact your nearest Independent Authorized Service Dealer IASD or contact Generac Mobile Products at 800 926 9768 or www generacmobile com with any questions
38. ure Low hydraulic level Fuel Over temp Fuel temperature gt 140 F 1 Open heat circuit solenoid 2 Increase scroll fan RPM to max RPM via fan circuit sole noid and drop engine to idle 3 Monitor fuel temperature for five minutes Fuel temperature is still gt 140 F 1 Open heat circuit solenoid 2 Drop engine to idle 3 Unit will shut down after five minutes 22 Owner s Manual for Flameless Air Heater Installation Diagrams and Service Log Section 6 Installation Diagrams and Service Log LLLOSES9 zvO SAS nznsl S v0 0 00 AHdMnN DIVZVA dWnd TAN SOd Z Oy vc81 62L ALIOXa Lv osz WALI 602 00 00 AHdHhW Live OLN 246 IZIS ONIY z040S 69 v 0 GSAG nznsl 6LY0 0 00 AHd3nN Ov OlZv cCZL IMVZVA 9frld MOTD SOd L 8000 0 48 AHdHYNW GLIZ EZIL IMVZVA Cl ti S602 00 00 AHdM W SW 018 3ZIS ONIX D ny CSC WALI 0 11 00 00 AHdYNN 8 IZIS ONIN Ier Wall w2 t 3ZIS ONIX Engine Harness 1 of 3 Y806 00 00 AHdShW Z 133HS 9 0Sv d OL V Z 133HS IN d W4l oL 8 8040S 59 6 0 GAS NZNSI 60v0 0 00 A Hd MIA NOLLYASNI 33M pyZelyl rreelyl dV 6040S 59 0v0 SAG nZhSl zGv0 90 00 AHdsnW MIA NOLLYSSNI 38IM L ZSZELPI 7SZELYL INV
39. ure to do so could result in death serious injury propery or equipment damage 000235 Owner s Manual for Flameless Air Heater Battery Hazards HAM eoa Explosion Batteries emit explosive gases while charging Keep fire and spark away Wear protective gear when working with batteries Failure to do so could result in death or serious injury JY 9001372 M WEG Explosion Do not dispose of batteries in a fire Batteries are explosive Electrolyte solution can cause burns and blindness If electrolyte contacts skin or eyes flush with water and seek immediate medical attention 000162 Risk of burn Do no open or mutilate batteries Batteries contain electrolyte solution which can cause burns and blindness If electrolyte contacts skin or eyes flush with water and seek immediate medical attention 000163a Accidental Start up Disconnect the negative battery cable then the positive battery cable when working on unit Failure to do so could result in death or serious injury 000130 Vision Loss Eye protection is required to avoid spray from spark plug hole when cranking engine Failure to do so could result in vision loss 000181 Environmental Hazard Always recycle batteries at an official recycling center in accordance with all local laws and regulations Failure to do so could result in environmental damage death or serious injury 000228 Owner s Manual for F
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