Staheli West DewPoint 331 Owner's Manual

Hay steamer

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DewPoint 331

Owner's Manual

2020 DewPoint 331

2021 DewPoint 331

2022 DewPoint 331

R3.2: 12.1.21

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Page 1 DewPoint 331 Owner's Manual 2020 DewPoint 331 2021 DewPoint 331 2022 DewPoint 331 R3.2: 12.1.21...
Page 2 Quick Navigation Buttons...
Page 3 RAISING INDIVIDUAL, FAMILY, AND COMMUNITY STANDARDS WHILE REVOLUTIONIZING THE AGRICULTURAL INDUSTRY. FOR THE MOST UP-TO-DATE SERVICE INFORMATION DOWNLOAD THE STAHELI WEST APP: Download the App When you see a QR code in this handbook, scan the code with your smart phone or tablet to see the associated video or content.
Page 4: Table Of Contents
Contents Foreword Operation DewPoint 331 Operator Training ......1 DewPoint 331 Operator Training ......45 Warranty Information ..........3 Common Operating Times........47 Touch Screen ............48 How to Start Steaming ...........49 Safety Common Valve Settings ..........51 Simple Operation ............ 52 Safety Decals ............5 Steam Rate Adjustment With a Gazeeka ....53...
Page 5 Contents Technical Information Troubleshooting Components Location List ........83 How to Reset a Fault ..........115 Diagram 1 ............... 84 Fault 1000: Flame Detected in Standby ....116 Diagram 2 ............... 85 Fault 1001: Flame Detected in Start .......116 Diagram 3 ............... 86 Fault 1002: Flame Detected in Pre-Purge ....116 Diagram 4 ...............
Page 6 Contents Fault 1045: High Pressure Detected in Fault 1113: Burner Controller Output Supply 4 Main Ignition ..........122 Voltage High ..........126 Fault 1046: High Pressure Detected in Run ....122 Fault 1114: Burner Controller Output Supply 4 Fault 1047: High Pressure Detected in Post-Purge .122 Amperage High ..........126 Fault 1050: Operating Pressure Tripped in Start ..123 Fault 1115: Flame Detector 12 V Supply Too Low .126...
Page 7 Contents Fault 1212: Boiler Controller Output Supply 4 Fault 1240: Boiler Water Level 1 Sensor Voltage Low ........... 130 Amperage High ..........135 Fault 1213: Boiler Controller Output Supply 4 Fault 1241: Boiler Water Level 2 Sensor Voltage High ..........130 Not Connected ..........136 Fault 1214: Boiler Controller Output Supply 4 Fault 1242: Boiler Water Level 2 Sensor Amperage High ..........130...
Page 8 Contents Fault 1267: Fan Speed Over 4500 RPM ....143 Fault 1307: Top Rear Actuator Not Calibrated ..151 Fault 1269: Open Center Fan Speed Valve Fault 1308: Top Rear Actuator Stuck / Jammed ..151 Short To Ground ..........144 Fault 1309: Bottom Rear Actuator Disconnected ...152 Fault 1270: Fan ON/OFF Solenoid Disconnected ..144 Fault 1310: Bottom Rear Actuator Not Calibrated .152 Fault 1271: Fan ON/OFF Solenoid...
Page 9 Contents Tests Maintenance Test 1001: Fuel solenoid .........163 Daily Maintenance ..........173 Test 1002: Spark Test ..........164 Pre-Operation ..........174 Test 1003: Electrode Gap ........165 Post-Operation ..........176 Test 1004: Valve Repair...........166 50 Hour Maintenance..........177 Test 1005: HPLS Calibration ........167 250 Hour Maintenance / Yearly ......181 Test 1006: OPLS Calibration ........168 500 Hour Maintenance...........185 Test 1007: Burner Tune...........169...
Page 10: Dewpoint 331 Operator Training
DewPoint 331 Operator Training Open the “Owner’s Manual”. Read the “Owner’s Manual” before operating the DewPoint machine. Train on where resources are found (Customer Resources, Support Tab, Owner’s Manual). Train on local boiler requirements. Show where emergency shut-offs are located.
Page 11 DewPoint 331 Operator Training Teach the ideal baling moisture (see Baling with Steam page). Steamed bales should be tightly packed with good leaf pattern. Sides of bales should be smooth but not smeared. Never exceed suggested internal bale temperature (see Baling with Steam page).
Page 12: Warranty Information
The warranty period for the DewPoint machine starts from the date of first use. Staheli West Parts offers a 1-year warranty on all parts from the date of purchase. Staheli West Parts does not cover labor costs of replacing a warrantied part.
Page 13: Safety
Safety Safety Safety Decals ............5 Tractor Requirements ..........7 Machine Faults ............8 Safe Procedures ............9 Boiler Jurisdiction ........... 11 Boiler Safety Test ............ 12 © 2021 Staheli West...
Page 14: Safety Decals
NO RETIRE NINGUN Calientes Caldera Adentro COMPONENTE DE LA Cercanas CALDERA BAJO PRESIÓN Hot Surfaces Inside Do Not Superficies Climb Calientes Adentro No Subir Watch Your Step Subir con Cuidado Pinch Point Hazard Peligro de Pellizco © 2021 Staheli West...
Page 15 * Véase la sección de toma de fuerza en el “In- * Véase la sección de toma de fuerza en el “In- struction Manual” para más detalles struction Manual” para más detalles. struction Manual” para más detalles © 2021 Staheli West...
Page 16: Tractor Requirements
Pioneer QAN88FOB will fit the Parker 0303-050 Pickup 1 Pioneer QAN88FOB male fitting direct to tractor Hydraulic Tank Pickup 2 hydraulic tank 1/4” Hose Pioneer QAN88FOB 1/4” Hose H3-H6 Available Upon Request All Fit Standard SCV © 2021 Staheli West...
Page 17: Machine Faults
The machine may continue to operate but machine performance may be hindered. Faults have to be corrected and reset or the machine will not operate. Faults will remain active but the machine may still operate. © 2021 Staheli West...
Page 18: Safe Procedures
Never Allow the Boiler to Run Dry If the low water cut off sensors ever fail and the boiler is allowed to run without water, serious injury or death may occur. © 2021 Staheli West...
Page 19 Electrical/Battery Safety Use caution when working: 1) around any loose electrical wires 2) near pump Sight Glass Remember that the sight glass is actually GLASS, not plastic or rubber. It can break and can cut you. © 2021 Staheli West...
Page 20: Boiler Jurisdiction
Boiler Jurisdiction It is your responsibility to make sure your boiler is up to code and meets the legal requirements in your area. For boiler jurisdiction information in your area, navigate to: https://www.nationalboard.org/PrintAllSynopsis.aspx?Jurisdiction=Select © 2021 Staheli West...
Page 21: Boiler Safety Test
Use a flat head screwdriver to open up the High Pressure Limit Switch. Set the multi meter to Ohms Ω. Connect the probes to the two wires as shown. There should be continuity until the pressure switch trips. © 2021 Staheli West...
Page 22 20 psi. Relieve pressure in the boiler by opening up one of Use a flat head screwdriver to open up the Operating the pigtail valves until it is around 10 psi. Pressure Limit Switch. © 2021 Staheli West...
Page 23 If the OPLS doesn’t trip within ±0.25 psi of 14.5, refer to Test 1006 Boiler pressure, HPLS, and OPLS status can all be Make sure the boiler has operating level of water. observed in the IO screen. © 2021 Staheli West...
Page 24 Both boiler low water 1 & 2 tripped to “Open” If boiler water drains below the sight glass and one or Close the boiler drain valve. both of the low waters still shows “Closed”, replace the associated boiler water level sensor. © 2021 Staheli West...
Page 25: Pre-Operation Requirements
Wheel Inspection ..........34 Tractor Preparation ..........34 DewPoint Hookup to Tractor ........36 DewPoint Hookup to Baler ........37 Fill Fuel Tanks............38 Fill Water Tanks ............39 Start DewPoint ............40 Burner Tune ............41 Brake Controller ............. 42 © 2021 Staheli West...
Page 26: Water
Staheli West Dealer and SHIP the sample(s) to the test lab on the label Water Analysis and Treatment Equipment Specification ● The test lab will analyze your water sample(s) and send a report to Staheli West. ● Staheli West will recommend the necessary water treatment equipment and send that recommendation...
Page 27: Water System Equipment Setup
Test the operation of the float valve to be sure it will stop the water flow when the bulk water storage tank is full ● You should leave your water system active during the season to keep the bulk water storage tank(s) full and ready for harvest operations © 2021 Staheli West...
Page 28: Water Transportation
A 2-inch engine driven transfer pump is normally used to transfer water from the water transport vehicle into the DewPoint machine ● Tailor your water/service transport vehicle to your own needs Bulk Water Storage Tank Water Softener Unit Reverse Osmosis (RO) Unit Water Transfer Pump © 2021 Staheli West...
Page 31: Water Setup
Water Setup Water Softener Unit Reverse Osmosis (RO) Unit Water Treatment Chemical Bulk Water Storage Tank 55 Gallon 0.5 Gallon Container Light Restricting to Prevent Algae Growth 0.5 Gallon Chemical Water Transfer Pump Ratio 1:1000 Chemical:Water © 2021 Staheli West...
Page 32: Water Equipment Selection
Parts Per Million (PPM) of Source Water Run Time Loss Amount of Water Expelled in Blowdown Carry (Reduction in Over Run Time) Will Occur 1100- Blowdown open 100% of time Parts Per Million (PPM) of Feed Water © 2021 Staheli West...
Page 33 600 PPM <50 PPM Reverse Osmosis Cons: Hard Water RO Water • Higher initial cost • Higher operating cost • Non-Toxic waste water created ○ Irrigation -Requires 240v ○ Dust abatement • Needs 240v power © 2021 Staheli West...
Page 34: Water Treatment Chemical
Organic Part #11634 Part #10034 55 Gallon Organic Part #11635 Part #10790 15 Gallon Boiler Guard™ has 3 purposes: 1. Scale Prevention 2. Rust Prevention 3. Foam Prevention Mix with supply water at a 1:1000 ratio. © 2021 Staheli West...
Page 35: Water Quality/Blowdown Principles
• The blowdown process removes some of the contaminated water in a controlled manner and allows new clean supply water to replace the old. © 2021 Staheli West...
Page 36 • Observe all local regulations regarding the discharge of boiler water ALWAYS USE A WATER SOFTENER OR A REVERSE OSMOSIS SYSTEM ALWAYS USE WATER TREATMENT CHEMICAL BOILER DAMAGE WILL OCCUR IF THESE STEPS ARE NOT TAKEN © 2021 Staheli West...
Page 37: Water Quality Settings
1. Turn on the screen and navigate to the “Water Quality” 2. Enter the PPM (Parts per Million) for that particular source Failure to enter an accurate PPM will result in either too much or too little water being purged during each blowdown © 2021 Staheli West...
Page 38: Baler Preparation
INSTALL GAZEEKA moisture gauge as instructed in the Gazeeka instruction manual • CALIBRATE prior to putting hay in the baler the first time. Follow all directions with the GAZEEKA instrument to calibrate and establish proper settings for safe and reliable operation. © 2021 Staheli West...
Page 39: Dewpoint Machine Preparation
CONNECT the end of each camera cable to the camera extension cables which are just inside and below the rear door. □ Use cable zip ties to secure all camera cables to the wire harnesses that run to the tail/work light assemblies Pickup Pickup PSI Gauge / Knotters Bale Chute © 2021 Staheli West...
Page 40: Valve Inspection
Boiler Drain Isolation Valve Valve Feed Water Feed Water Isolation Valve Actuator Supply Water Tanks Supply Water Tanks Supply Water Supply Water Feed Water Fill Valve Filter (T-Strainer) Pump *All valves are shown in normal operating positions © 2021 Staheli West...
Page 41: Actuator Inspection
Inputs / Outputs to be running to test the actuators). page. Press to activate Manual Mode. Use the Twist Knob to select and test all 7 actuators. Visually inspect valves and actuators for damage. © 2021 Staheli West...
Page 42 Actuator Inspection Bottom Steam Actuator Steam Purge Actuator Top Steam Actuator Water Purge Actuator Feed Water Actuator Blowdown Actuator Louver Actuator © 2021 Staheli West...
Page 43: Wheel Inspection
Make sure all lug nuts are tightened to 81 ft-lbs Inflate tires to 40 psi Tires: BKT I-1 Farm Implement Size: 14L-16.1SL (12 Ply Flotation) Wheels: +0.38 OFFSET 16.1 X W11C Tractor Preparation Battery Box Wire Harness (11547) Tractor Cab Wire Harness (11546) © 2021 Staheli West...
Page 44 Connect the deutsch plug 12 V that has an open wire. Splice the open wire into a brake Tractor Trailer light or some other 12 V source that is only active when Light Plug the brakes are engaged. © 2021 Staheli West...
Page 45: Dewpoint Hookup To Tractor
Connect case drain, return, supply, P1, P2, and the lights. Connect the wire harnesses. *Connect case drain first and disconnect case drain last. Case drain must be a return to sump. Connect PTO. Secure anti-rotating shield clip as shown. © 2021 Staheli West...
Page 46: Dewpoint Hookup To Baler
Never operate with harsh PTO angles. necessary. Make sure the PTO knuckles are lined up on both the DewPoint machine and the baler. Failure to do so will result in heavy vibrations and excessive wear. © 2021 Staheli West...
Page 47: Fill Fuel Tanks
Fill the fuel tanks with #2 Diesel. The tanks are connected so you only need to fill from one side. You need to give the fuel a little time to equalize after filling one tank and then add more. Leave 4” of space in the top of the tanks. © 2021 Staheli West...
Page 48: Fill Water Tanks
*Tip: Fill the boiler tanks. Always add 0.5 gallons of chemical for every with water and then top off the supply tanks for 500 gallons of water. (Ratio 1:1000) longer operating time. © 2021 Staheli West...
Page 49: Start Dewpoint
Press the “Power” icon. The machine will prepare for heat the water and create steam pressure. The steam field work. This will take 5-30 minutes depending on purge and hold mode indicate startup is complete. water temperature and water level. © 2021 Staheli West...
Page 50: Burner Tune
Press to deselect the Low Fire louver position. Press and wait for the burner to reach High Fire (boiler water temperature of 180° F or steam pressure of 5 psi) and repeat steps 3-5. © 2021 Staheli West...
Page 51: Brake Controller
(indicated with X) for typical T relationships. For example: With the boost off, [ ], during a brak- © 2021 Staheli West relationships. For example: With the boost off, [ ], during a brak- ing event, the power to the brakes starts out at zero and...
Page 53: Operation
Operation Operation DewPoint 331 Operator Training ......45 Common Operating Times........47 Touch Screen ............48 How to Start Steaming ...........49 Common Valve Settings ..........51 Simple Operation ............ 52 Steam Rate Adjustment With a Gazeeka ....53 Steam Rate Adjustment Without a Gazeeka ..54 Common Operation ..........55...
Page 54: Dewpoint 331 Operator Training
DewPoint 331 Operator Training Open the “Owner’s Manual”. Read the “Owner’s Manual” before operating the DewPoint machine. Train on where resources are found (Customer Resources, Support Tab, Owner’s Manual). Train on local boiler requirements. Show where emergency shut-offs are located.
Page 55 DewPoint 331 Operator Training Teach the ideal baling moisture (see Baling with Steam page). Steamed bales should be tightly packed with good leaf pattern. Sides of bales should be smooth but not smeared. Never exceed suggested internal bale temperature (see Baling with Steam page).
Page 56: Common Operating Times
140° F. They often bale into the evening until the windrows become too saturated with dew. 10 11 12 10 11 12 Often too wet 10 11 12 10 11 12 Often too wet Not enough dew / moisture © 2021 Staheli West...
Page 57: Touch Screen
Top Steam (On/Off) Top Steam Output Power Burner Enable Water System Enable Hold Mode Blowdown Enable Menu Increase Bottom Steam Ratio/ Decrease Top Steam Ratio Steam (On/Off) Steam Rate Indicator Bottom Steam Output Bottom Steam (On/Off) © 2021 Staheli West...
Page 58: How To Start Steaming
The progress bar shows the progress. During this time field work. This will take 5-30 minutes depending on the boiler fills with water, and the burner turns on to water temperature and water level. heat the water and create steam pressure. © 2021 Staheli West...
Page 59 Knob will light up green green as well to while steam is on. show that steam is on. You are ready to start steaming. Look at the following suggested steam settings. (Common Valve Settings page) © 2021 Staheli West...
Page 60: Common Valve Settings
Steam Ratio Indicator the Steam Ratio Indicator in the middle and the closer to the top and the steam rate at 40%. steam rate at 100%. Adjust steam rate as needed. Adjust steam rate as needed. © 2021 Staheli West...
Page 61: Simple Operation
#5 - Adjust Steam Rate 5-10% If Necessary #6 - Repeat Steps 4-5 Until Optimum Bale Moisture is Reached Make steam rate changes based on the average (Avg) reading *The steam ratio should not be changed unless the windrow condition changes © 2021 Staheli West...
Page 62: Steam Rate Adjustment With A Gazeeka
(Avg) reading #4 - Wait for at least two bales before making more steam rate changes Wait 2 Bales Gazeeka Reading Steam Rate Change REMEMBER TO WAIT AT LEAST TWO BALES BETWEEN MAKING ADJUSTMENTS © 2021 Staheli West...
Page 63: Steam Rate Adjustment Without A Gazeeka
Wait 24-72 hours to obtain a precise reading. #3 - Wait for at least two bales before making more steam rate changes Wait 2 Bales Steamed Bale Steam Rate Change REMEMBER TO WAIT AT LEAST TWO BALES BETWEEN MAKING ADJUSTMENTS © 2021 Staheli West...
Page 64: Common Operation
Common Operation Turn steam off when: Turning around at the end of windrows Slowing down Light/Absent windrow spots © 2021 Staheli West...
Page 65: Short Term Storage (Wet Layup)
As soon as water comes out, set the feed water actuator back to 0%. The machine is now ready for short term storage. Having the boiler completely full of water prevents rust and corrosion inside the boiler. Days of Storage Storage Recommendations None Short Term Storage 3-30 (Wet Layup) >30 Winterize © 2021 Staheli West...
Page 66: Keep Hot
Hold/Pause button. Leave the tractor and steamer running the entire time the machine will be subjected to below freezing temperatures. Using keep hot will prevent sensors, plumbing, and other components on the steamer from freezing. © 2021 Staheli West...
Page 67: Blowdown System
Hot water will shoot out of the red blowdown hose behind baler pickup Make sure no one is underneath the baler before pressing Don’t perform blowdown when stopped © 2021 Staheli West...
Page 68 The surface blowdown that the operator performs while running the machine removes these contaminants from the surface of the boiling water. The blowdown valve is open when the “Blowdown” indicator is black Behind baler pickup not spraying tires © 2021 Staheli West...
Page 69: Water Purge System
This fault will not prevent the machine from working but the problem should be addressed soon. The water purge valve is open when the “Water Purge” indicator is blue Water Purge Sensor Water Purge Actuator © 2021 Staheli West...
Page 70: Steam Purge System
System OFF System ON The steam purge system turns on automatically at 50% and above. It turns off automatically at 49% and below. The steam purge valve is open when the “Steam Purge” indicator is black © 2021 Staheli West...
Page 71: Irrigation
Since natural dew tends to form more heavily in low areas of a field, it is a good practice to water the low side of the field first and the high side last during the final rotation before your hay harvest. This will make your dry-down more consistent across the entire field. © 2021 Staheli West...
Page 72: Cutting
Since DewPoint technology allows operators to bale 12-24 hours per day, (almost anytime the hay is dry) hay producers can “schedule” their harvest. □ Simply decide how many acres you want to bale each day and go ahead and cut that many acres each day. © 2021 Staheli West...
Page 73: Raking
Moisture from the soil will percolate up into the bottom of a double windrow, particularly when yields are heavy. • In this case, it may be necessary to “flip” the double windrow to get sufficient dry-down for baling. © 2021 Staheli West...
Page 74 If rake teeth are set too high, you will leave valuable crop tonnage on the ground in the field. □ Maintaining rake teeth and the rake in general, and careful daily adjustment, are worth the effort. © 2021 Staheli West...
Page 75: Dewpoint Machines
Hydraulic GPM • 1 Set SCV • Hydraulic Trailer Brake Hydraulics • 3/8” Direct Return to Valve Hydraulic Tank • 12 Volt Auxillary Port • SW Harness 11546 Electrical • SW Harness 11547 • Trailer Brake Controller © 2021 Staheli West...
Page 76: Baling With Steam
Condition of Alfalfa Fully Cured (6-10%) Before Steaming Fully Cured (6-10%) Condition of Cereal Grain Don’t be tricked by green nodes on plants that Before Steaming appear dry Condition of Mixed Grass/Alfalfa Before Fully Cured (6-10%) Steaming © 2021 Staheli West...
Page 77: Suggested Moisture With Steam
Suggested Moisture With Steam Large Square Bales Small Square Bales Legumes Alfalfa 12-14% 14-22% Alfalfa/Grass Grasses Forage Grasses Timothy Wheat Cereal Triticale Grains Beardless Barley Straw © 2021 Staheli West...
Page 78: Steaming Different Crops
“springy” characteristics of bales, better effects with hay press machinery. Timothy Wheat Higher density, more weight, less dust, consistent bales, Cereal Triticale reduces “springy” characteristics of bales, better effects Grains with hay press machinery. Beardless Barley Straw © 2021 Staheli West...
Page 79: Steam Effects In Different Temperatures
The higher the temperature and the steam rate, the more cohesive the flakes will be. This is one reason why operators may choose to bale during cooler temperatures. © 2021 Staheli West...
Page 80: Judging Bale Moisture
We also recommend that you watch bale chamber pressure readings and visually observe the bales you are making as you pass by them on the next windrow. These redundant observations will help assure that you are making the best hay possible. © 2021 Staheli West...
Page 81: Moisture Sensors
Accurate Steam moisture dispersion 1 Day Reading (Moisture level will drop Accurate 3-5% from initial reading) Initial Reading with Accurate Reads low 3-5% Steam 1-Day Reading Accurate It is NEVER recommended to bale with stem moisture © 2021 Staheli West...
Page 82: Judging Bale Moisture With The Gazeeka Moisture Gauge
8-10% moisture in the windrow, depending on ambient humidity. ▫ In these climates you will normally be able to make bales with very good leaf retention and density by applying enough steam to bring the bale moisture up to 12-18%. © 2021 Staheli West...
Page 83 ADJUST the steam injection rate over the first 5 to 10 bales using the Master Steam Rate twist knob to achieve the desired moisture level in your bales. • MONITOR and make adjustments throughout the operating time to keep the bale moisture at the desired level. © 2021 Staheli West...
Page 84: Judging Bale Moisture Visually
NOTE: There is an acceptable range of moisture where bale density, flake wafering and other characteristics can be manipulated and controlled according to the demands of your hay market. You should become familiar with these characteristics. © 2021 Staheli West...
Page 85: Judging Bale Moisture With A Handheld Moisture Probe
If the windrow is very dry, requiring a higher rate of steam to bring the bale moisture to an optimum level, there will be a much larger offset in the moisture reading compared to the actual moisture in the bale. © 2021 Staheli West...
Page 86 • This type of moisture probe is effective several hours after the hay has been baled, as the applied moisture diffuses throughout the plant tissue more completely. © 2021 Staheli West...
Page 87: Judging Bale Moisture After Baling
The beauty of DewPoint technology is that you can choose the way you want to bale your hay, as well as the bale formation characteristics you and you market want in the finished product. © 2021 Staheli West...
Page 88: Judging Bale Temperature
LEARN YOUR OWN LIMITS Some types of hay may be more sensitive to heat than others. We recommend that you define temperature levels that are acceptable on your operation. Temperature Probe (Large Square Bales) Part # 11345 © 2021 Staheli West...
Page 89: Hauling, Stacking, And Storage Of Steam-Treated-Hay
● If bales of hay must be moved off the field immediately after baling to avoid weather damage, but they are too hot to stack, wait 1-2 hours and recheck temperature. Small bales dissipate heat much quicker than large bales. © 2021 Staheli West...
Page 91: Technical Information
Field Work Screen ........... 97 How The 331 Works ..........98 Machine Specifications ...........99 Sensors..............100 Outputs..............104 Actuators ..............105 Fuses ..............106 Off Delay Relay ............107 Burner Wiring ............108 Fuel Pump .............. 109 © 2021 Staheli West...
Page 92: Components Location List
High Fire Nozzle 33080 High Fire Pressure Sensor 32982 High Fire Solenoid Valve 33058 High Pressure Limit Switch (HPLS) 10379 Hydraulic Block 12, 14 28080 Hydraulic Case Drain Pressure 24132 Sensor Hydraulic Oil Cooler 8, 12, 14 32942 © 2021 Staheli West...
Page 94: Diagram 2
Bottom Steam Actuator Top Steam Actuator Flue Oxygen Sensor Steam Purge Actuator Flue Temperature Sensor Water Purge Water Purge Actuator Rear Furnace Sensor Door Feed Water Actuator Blowdown Supply Feed Water Actuator Water Filter Pump (T-Strainer) © 2021 Staheli West...
Page 95: Diagram 3
Sensor 1 Boiler Water Level Sensor 2 Manual Steam Pressure Gauge Operating Pressure Limit Switch (OPLS) High Pressure Limit Switch (HPLS) Steam Pressure Sensor Boiler Sight Glass Front Turn Box Feed Water Boiler Water Pump Temperature Sensor © 2021 Staheli West...
Page 96: Diagram 4
Pressure Sensor Low Fire Fan Motor Pressure Sensor Overhung Fan Speed Load Adapter Sensor Fuel Pump Pressure Sensor High Fire Solenoid Valve Low Fire Solenoid Valve Safety fuel solenoid Valve Fuel Pump Fan Motor Pressure Gauge © 2021 Staheli West...
Page 97: Diagram 6
Diagram 6 High Fire Low Fire Electrode + Flame Detector Electrode - Flame Detector Diagram 7 High Fire Nozzle Flame Detector Tube Electrode + Electrode + Electrode - Electrode - Low Fire Nozzle © 2021 Staheli West...
Page 98: Diagram 8
Diagram 8 Hydraulic Block IOX Module Burner Controller Boiler Controller Fuse Block Hydraulic Fuel Level Oil Filter Sensor Hydraulic Supply Supply Water Filter Sensor Level Sensor Hydraulic Oil Cooler (Optional) Hydraulic Valve Block © 2021 Staheli West...
Page 99: Diagram 9
Diagram 9 Supply Water Boiler Drain Isolation Valve Valve Feed Water Feed Water Isolation Valve Actuator Supply Water Tanks Supply Water Tanks Supply Water Supply Water Feed Water Fill Valve Filter (T-Strainer) Pump © 2021 Staheli West...
Page 100 Pressure Sensor Pump Supply Water Supply Water Level Sensor Supply Water Supply Fill Valve Water Filter (T-Strainer) Feed Water Pump Feed Water Sparge Tube Feed Water Actuator Check Valve Feed Water Pump Feed Pump Protection Sensor © 2021 Staheli West...
Page 101 Diagram 11 From Water Front Right Purge Tank Feed Pump Supply Protection Sensor Water Level Sensor To Hydraulic Oil Cooler (Optional) Water Purge Actuator Supply Supply Water Feed Water Water Filter Fill Valve Pump (T-Strainer) © 2021 Staheli West...
Page 102 Diagram 12 Hydraulic System Feed Water Pump Hydraulic Block Hydraulic Oil Filter Fan Motor Hydraulic Oil Cooler (Optional) © 2021 Staheli West...
Page 103 Fan Speed Hydraulic Return Control Pressure Open Center Fan ON/OFF Solenoid Feed Pump ON/OFF Solenoid Hydraulic Supply Pressure Hydraulic Case Drain Pressure Fan Speed Control Closed Center Feed Water Pump Hydraulic Pressure Flow Control Relief Valve © 2021 Staheli West...
Page 104: Diagram 14
Diagram 14 Hydraulic Oil Cooler (Optional) Hydraulic Oil Filter Hydraulic Block Feed Water Pump Fan Motor Supply Contingency Hose Return Case Drain © 2021 Staheli West...
Page 105: Hydraulic Systems
Feed Water Pump 6-8 GPM 6-8 GPM 20 GPM Hydraulics Closed Center hydraulic systems will create less heat because they send only the necessary gpm to the DewPoint. Closed Center hydraulic systems are preferred for this reason. © 2021 Staheli West...
Page 106: Field Work Screen
Top Steam (On/Off) Top Steam Output Power Burner Enable Water System Enable Hold Mode Blowdown Enable Menu Increase Bottom Steam Ratio/ Decrease Top Steam Ratio Steam (On/Off) Steam Rate Indicator Bottom Steam Output Bottom Steam (On/Off) © 2021 Staheli West...
Page 107: How The 331 Works
Steam rate and distribution is controlled by the machine operator from the touch screen located in the tractor cab. The DewPoint 331 generates steam which is injected into hay windrows. The ability to inject steam gives farmers the following benefits: • Added Bale Weight •...
Page 108: Machine Specifications
40-80 Tons / Load Hours 35-70 Metric Tons / Load 250 Gal. Boiler Water 950 L 120 Gal. 7.5 - 15 120-240 Tons / Load Fuel / Diesel 450 L Hours 110-220 Metric Tons / Load © 2021 Staheli West...
Page 109: Sensors
4-20mA Signal 0-30 psi 6-13 psi 12.00v Supply Water Level DT06-4S 0-5 psi/ 4-20mA 0-500 Signal 0-500 <50 gallons gallons gallons 12.00v Fuel Level DT06-4S 0-5 psi/ 4-20mA 0-150 0-150 <50 gallons Signal gallons gallons 12.00v © 2021 Staheli West...
Page 110 <40 psi or 12.00v 0-3500 psi >40 psi fan speed <3600 4-20mA Signal Hydraulic Return Pressure DT06-3S 12.00v 0-3500 psi >350 psi 4-20mA Signal Hydraulic Case Drain DT06-3S Pressure 12.00v 0-3500 psi >50 psi 4-20mA Signal © 2021 Staheli West...
Page 111 Boiler Water Level 2/ DT06-4S 0-12 Inches Low Water 2 Normally >10 inches LOW WTR 2 3-7 inches ON 12 V 12.00v Closed >8 inches >2 inches OFF 0 V (Pictured differential Open) 4-20mA 12 V © 2021 Staheli West...
Page 112 Water Purge 10 min DT06-3S Closed/ water 12 V Normally On (when detection Open detecting while water) steaming Signal Oxygen DTM06-4S Low Fire Outside 1.85-2.3 CAN 2 12 V of Normal High Fire Range 1.15-2.22 CAN 2 © 2021 Staheli West...
Page 113: Outputs
12 V Fan Speed Control DT06-2S High Fire Fuel IP 67 DIN Open Center Solenoid 12 V 12 V Fan Speed Control DT06-2S Closed Center 12 V Spark Coil Delphi 4 pin 12 V 5 V ON © 2021 Staheli West...
Page 114: Actuators
12 V Top Steam Actuator CAN 2 CAN 2 DT06-4S Bottom Steam 12 V Actuator CAN 2 CAN 2 DT06-4S 12 V Feed Water Actuator CAN 2 CAN 2 *See Test 1008 for CAN address setting. © 2021 Staheli West...
Page 115: Fuses
Water Purge Sensor Spare IOX Supply Voltage Diagnostic Port Spare Boiler Controller Supply Voltage Spare Burner Controller Supply Voltage Spark Coil Orientation Key Tractor Harness Fuse Block Battery Box Main Fuse Display Gazeeka Camera Auto Reset Brakes © 2021 Staheli West...
Page 116: Off Delay Relay
The off delay relay is very important and should NEVER be replaced with a common 12 v relay. 1-OFF 2-ON Off Delay Battery Cut Relay Display Off Relay Power 12 v Off Delay Battery Cut Relay Display Off Relay Power 2.5 Second Off Delay © 2021 Staheli West...
Page 118: Fuel Pump
Increase psi Decrease psi Nozzle psi ~227 Nozzle 1 (Low Fire) ~220 Nozzle 1 & 2 (High Fire) High Fire High Fire Low Fire Nozzle Flame Electrode + Detector Tube Flame Electrode - Low Fire Detector Nozzle © 2021 Staheli West...
Page 120: Troubleshooting
Fault 1042: High Pressure Detected in Purge ..122 Supply 3 Amperage High .......125 Fault 1043: High Pressure Detected in Pre-Ignition 122 Fault 1112: Burner Controller Output Fault 1044: High Pressure Detected in Supply 4 Voltage Low ........126 Spark Ignition ..........122 © 2021 Staheli West...
Page 121 Fault 1210: Boiler Controller Output Fault 1238: Hydraulic Case Drain PSI Sensor Supply 3 Voltage High ........130 Amperage High ..........135 Fault 1211: Boiler Controller Output Fault 1239: Boiler Water Level 1 Sensor Supply 3 Amperage High .......130 Not Connected ..........135 © 2021 Staheli West...
Page 122 Fault 1304: Closed Center Fan Speed Valve (Over 8 Inches) ..........143 Short To Ground ..........151 Fault 1266: Boiler Water Level Too High Fault 1305: Water Purge System Warning ....151 (Over 10 Inches) ..........143 Fault 1306: Top Rear Actuator Disconnected ..151 © 2021 Staheli West...
Page 123 High Fire ............ 156 Fault 1329: Low Fire Nozzle Pressure Low While in Low Fire .............156 Fault 1330: Pressure Detected on High Fire Nozzle While in Low Fire...........157 Fault 1331: Fuel Pump Pressure Low .....157 © 2021 Staheli West...
Page 124: How To Reset A Fault
Fault Text Will Appear Here Press to close fault window. Press to reset fault. Faults have to be corrected and reset or the machine will not operate. Faults will remain active but the machine may still operate. © 2021 Staheli West...
Page 125: Fault 1000: Flame Detected In Standby
Blinking - No flame • Faulty flame detector. • Replace flame detector. Solid - Flame No LED - Problem/No power • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 126: Fault 1005: Flame Not Detected In Spark Ignition
• Check for ~5 V on pin C during spark ignition and constant 12 V on pin D. • Faulty wiring. • Repair/Replace wiring. Constant 12 V 5 V ON • See Test 1002 for spark testing. © 2021 Staheli West...
Page 127: Fault 1006: Flame Not Detected In Main Ignition
Causes Troubleshooting Fixes • Fan running in manual mode. • Turn off fan in manual mode and reset the fault. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 128: Fault 1012: Airflow Not Detected In Pre-Purge (See Fault 1260)
(Part 34490) hoses for obstructions. • Check all 4 airflow filters. • Faulty airflow switch. • Replace airflow switch. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 129: Fault 1020: Low Water 1 Detected In Start
1 sensor. • Blown fuse #24 (main fuse • Check fuse for blown • Replace fuse #24 (2 amp). block). symptoms. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 130: Fault 1030: Low Water 2 Detected In Start
2 sensor. • Blown fuse #25 (main fuse • Check fuse for blown • Replace fuse #25 (2 amp). block). symptoms. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 131: Fault 1040: High Pressure Detected In Start
• Blown fuse #22 (main fuse • Check fuse for blown • Replace fuse #22 (2 amp). block). symptoms. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 132: Fault 1050: Operating Pressure Tripped In Start
PSI gauge). • Faulty steam pressure sensor. • Replace steam pressure sensor. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 133: Fault 1060: Louver Open (Too Long) In Start
• Replace fuse #27 (2 amp). • Faulty spark coil causing blown • Inspect spark coil wiring and • Replace spark coil. fuse #27. connection. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 134: Fault 1104: Burner Controller Output Supply 1 Voltage High
Fault 1110: Burner Controller Output Supply 3 Voltage High Check tractor battery. If problem persists: contact dealer / replace controller. Fault 1111: Burner Controller Output Supply 3 Amperage High Check tractor battery. If problem persists: contact dealer / replace controller. © 2021 Staheli West...
Page 135: Fault 1112: Burner Controller Output Supply 4 Voltage Low
Check tractor battery. If problem persists: contact dealer / replace controller. Fault 1120: Burner Controller 5 V Supply Too High Triggers when voltage is over 5.5 V Check tractor battery. If problem persists: contact dealer / replace controller. © 2021 Staheli West...
Page 136: Fault 1121: Flame Detector Signal Voltage Low
Indicates an open circuit during use. Causes Troubleshooting Fixes • Solenoid disconnected. • Connect solenoid. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. • Faulty solenoid. • Replace solenoid. © 2021 Staheli West...
Page 137: Fault 1128: High Fire On/Off Solenoid Short To Ground
Fault 1132: Spark Coil Short To Ground Indicates the amperage draw is too high. Causes Troubleshooting Fixes • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. • Faulty solenoid. • Replace solenoid. © 2021 Staheli West...
Page 138: Fault 1200: Boiler Controller Watchdog Reset
• Faulty hydraulic fan speed • Replace hydraulic fan speed • Inspect hydraulic fan speed control valve (open center or control valve (open center or control valve wiring and closed center) causing blown fuse closed center). connection. #19. © 2021 Staheli West...
Page 139: Fault 1210: Boiler Controller Output Supply 3 Voltage High
Check tractor battery. If problem persists: contact dealer / replace controller. Fault 1218: Boiler Controller 8.5 V Supply Too High Triggers when voltage is over 8.85 V Check tractor battery. If problem persists: contact dealer / replace controller. © 2021 Staheli West...
Page 140: Fault 1219: Boiler Controller 5 V "Sensor" Supply Too Low
• Use REDEW boiler de-scaler (Part # 11194). • Remove a hand-hole cover and • Scale has built up in the boiler. inspect boiler tubes for scale. • Use water treatment chemical (preventative). © 2021 Staheli West...
Page 141: Fault 1225: Boiler Water Temp Sensor Not Connected
Indicates >4.5 volts is present on the signal wire. Causes Troubleshooting Fixes • Swap with compatible sensor • Faulty sensor. • Replace sensor. (See sensor page). • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 142: Fault 1229: Furnace Door Temp Is High Alarm (190F)
Indicates >4.5 volts is present on the signal wire. Causes Troubleshooting Fixes • Swap with compatible sensor • Faulty sensor. • Replace sensor. (See sensor page). • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 143: Fault 1233: Hydraulic Return Psi Sensor Not Connected
Indicates >22mA is present on the signal wire for 5 seconds. Causes Troubleshooting Fixes • Swap with compatible sensor • Faulty sensor. • Replace sensor. (See sensor page). • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 144: Fault 1237: Hydraulic Case Drain Psi Sensor Not Connected
Indicates >22mA is present on the signal wire for 5 seconds. Causes Troubleshooting Fixes • Swap with compatible sensor • Faulty sensor. • Replace sensor. (See sensor page). • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 145: Fault 1241: Boiler Water Level 2 Sensor Not Connected
Indicates >22mA is present on the signal wire for 5 seconds. Causes Troubleshooting Fixes • Swap with compatible sensor • Faulty sensor. • Replace sensor. (See sensor page). • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 146: Fault 1245: Fuel Pump Psi Sensor Not Connected
Indicates >22mA is present on the signal wire for 5 seconds. Causes Troubleshooting Fixes • Swap with compatible sensor • Faulty sensor. • Replace sensor. (See sensor page). • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 147: Fault 1249: High Fire Nozzle Psi Sensor Not Connected
Indicates >22mA is present on the signal wire for 5 seconds. Causes Troubleshooting Fixes • Swap with compatible sensor • Faulty sensor. • Replace sensor. (See sensor page). • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 148: Fault 1253: Feed Pump Protection Psi Sensor Not Connected
Indicates >22mA is present on the signal wire for 5 seconds. Causes Troubleshooting Fixes • Swap with compatible sensor • Faulty sensor. • Replace sensor. (See sensor page). • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 149: Fault 1257: Steam Pressure Sensor Reading High (Over 18 Psi)
Indicates >22mA is present on the signal wire for 5 seconds. Causes Troubleshooting Fixes • Swap with compatible sensor • Faulty sensor. • Replace sensor. (See sensor page). • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 150: Fault 1260: Fan Did Not Start, Zero Rpm Detected
• Replace feed pump protection sensor. sensor. • Verify that the sensor is a 0-30 • Wrong sensor installed. • Install correct sensor. psi sensor. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 151: Fault 1262: Feed Pump Start Protection: Psi Too Low (Less Than 5 Psi)
• Perform “Test 1009” to • Replace boiler water level • Faulty boiler water level sensor. determine which sensor is faulty. sensor. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 152: Fault 1265: Boiler Water Level Too High (Over 8 Inches)
• Disconnected fan speed control setting is selected on the touch closed center. valve. screen. • Connect fan speed control valve. • Reduce flow to <25 gpm. • Excessive flow from open center tractor hydraulics. • Buy a new tractor. © 2021 Staheli West...
Page 153: Fault 1269: Open Center Fan Speed Valve Short To Ground
Fault 1273: Feed Water Pump ON/OFF Solenoid Short To Ground Indicates the amperage draw is too high. Causes Troubleshooting Fixes • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. • Faulty valve. • Replace valve. © 2021 Staheli West...
Page 154: Fault 1274: Initial Boiler Fill Is Taking Longer Than Expected
Fault 1275: Reaching Boiler Water Fill Target Is Taking Longer Than Expected This indicates it is taking longer than expected for the water to reach the boiler fill target. (3 minutes) See Fault 1274. • © 2021 Staheli West...
Page 155: Fault 1276: Water Purge Actuator Is Disconnected
• Replace actuator. Fault 1280: Blowdown Actuator Stuck / Jammed Indicates the internal encoder does not match the commanded actuator position. Causes Troubleshooting Fixes • Obstruction in valve. • Remove obstruction. • Faulty actuator. • Replace actuator. © 2021 Staheli West...
Page 156: Fault 1281: Steam Purge Actuator Is Disconnected
• Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. Fault 1285: Top Steam Actuator Is Not Calibrated Indicates the actuator has not been programmed by the factory. Causes Troubleshooting Fixes • Faulty actuator. • Replace actuator. © 2021 Staheli West...
Page 157: Fault 1286: Top Steam Actuator Stuck / Jammed
• Wrong CAN address on the feed • Change the address to 0, then re-address the actuator water actuator. (See Test 1008). • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 158: Fault 1291: Feed Water Actuator Is Not Calibrated
Fixes • Open center selected for closed • Select closed center. center tractor. • Return line not plugged in. • Plug in return line. • Faulty hydraulic return pressure • Replace hydraulic return pressure sensor. sensor. © 2021 Staheli West...
Page 159: Fault 1296: Hydraulic Case Drain Pressure High
• Replace fuse #3 (2 amp). block). symptoms. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. • Faulty IOX controller. • Replace IOX controller. • Faulty boiler controller. • Reprogram/Replace boiler controller. © 2021 Staheli West...
Page 160: Fault 1304: Closed Center Fan Speed Valve Short To Ground
• Replace actuator. Fault 1308: Top Rear Actuator Stuck / Jammed Indicates the internal encoder does not match the commanded actuator position. Causes Troubleshooting Fixes • Obstruction in valve. • Remove obstruction. • Faulty actuator. • Replace actuator. © 2021 Staheli West...
Page 161: Fault 1309: Bottom Rear Actuator Disconnected
Troubleshooting Fixes • Low/High fire failed to ignite. • Clean burner gun. • Faulty oxygen sensor. • Clean/Replace oxygen sensor. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 162: Fault 1314: Rich Burn Detected
Indicates the internal encoder does not match the commanded actuator position. Causes Troubleshooting Fixes • Obstruction in valve. • Remove obstruction. • Swap with compatible actuator • Faulty actuator. • Replace actuator. Part #34242 (See Test 1008). © 2021 Staheli West...
Page 163: Fault 1320: Bottom Steam Actuator Did Not Reach Commanded Position
• Faulty steam pressure sensor. using the manual gauge. Part #33140 • Swap boiler water temperature • Faulty boiler water temperature sensor with rear door • Replace boiler water sensor. temperature sensor. (Drain boiler temperature sensor. Part #32931 first) © 2021 Staheli West...
Page 164: Fault 1326: Fuel Not Detected During Ignition
• Clogged fuel filter. • Replace fuel filter. Part #10054 • Remove burner gun and inspect • Loose/Leaking fuel nozzle. • Tighten/Replace nozzle. nozzle. • Clogged fuel lines. • Use compressed air to clear the lines. © 2021 Staheli West...
Page 165: Fault 1328: Low Fire Nozzle Pressure Low While In High Fire
• Clogged fuel filter. • Replace fuel filter. Part #10054 • Remove burner gun and inspect • Loose/Leaking fuel nozzle. • Tighten/Replace nozzle. nozzle. • Clogged fuel lines. • Use compressed air to clear the lines. © 2021 Staheli West...
Page 166: Fault 1330: Pressure Detected On High Fire Nozzle While In Low Fire
• Tighten set screw. shaft coupler. turning. • Faulty fuel pump. • Replace fuel pump. Part #10045 • Clogged fuel filter. • Replace fuel filter. Part #10054 • Clogged fuel lines. • Use compressed air to clear the lines. © 2021 Staheli West...
Page 167: Fault 2000: Work Lights Will Not Turn On
• Replace 12 V main battery cut off relay (75amp). relay (75amp). • Faulty touch screen. • Replace touch screen. • Inspect the wiring for ground, • Faulty wiring. • Repair/Replace wiring. continuity, and proper voltage. © 2021 Staheli West...
Page 168: Fault 2002: Burner Smoking
• Remove gun assembly and • Leaky gun assembly. • Repair/Replace gun assembly. inspect for leaks. • Restricted fuel flow through the • Inspect fuel path, check for • Remove restrictions. fuel solenoid valves. overtightened fittings. © 2021 Staheli West...
Page 169: Fault 2003: Water In Steam / Bales Have Water Splotches / Sudden Loss Of Steam Pressure And Water Level
• Turning too sharp. • If there is rattling or knocking • Replace PTO bearings. sounds, this indicates that your • Stopping too abruptly. bearings have failed. • PTO front and rear knuckles aren’t aligned causing vibration. © 2021 Staheli West...
Page 170: Fault 2005: Pto Shaft Slipping
• Water will be leaking where the • Plug flue tube on both ends. burner mounts to the boiler, or Contact Staheli West for repair • Leaky flue tube. on the rear boiler door, or at the options (A boiler repair shop will front turn box.
Page 171 Test 1003: Electrode Gap ........165 Test 1004: Valve Repair...........166 Test 1005: HPLS Calibration ........167 Test 1006: OPLS Calibration ........168 Test 1007: Burner Tune...........169 Test 1008: Canbus Address Setting ......170 Test 1009: Boiler Water Level Sensor .....171 © 2021 Staheli West...
Page 172: Test 1001: Fuel Solenoid
Put your hand on the fuel solenoid valves and confirm that it opens. You should feel a click as it opens. If it hums or buzzes, this indicates a faulty solenoid valve that needs cleaning or replacement. © 2021 Staheli West...
Page 173: Test 1002: Spark Test
4 seconds. Make sure it is sparking on Start the machine like normal. the tips of the electrodes and sparking inside the tube. If there is no spark, see fault 1005 for causes. See Test 1003 for electrode gap settings. © 2021 Staheli West...
Page 174: Test 1003: Electrode Gap
Test 1003: Electrode Gap High Fire Nozzle Flame Detector Tube Electrode + Electrode - Low Fire Nozzle Electrode + 7/64” 3/4” 19mm Electrode - 19/32” 15mm © 2021 Staheli West...
Page 175: Test 1004: Valve Repair
3. Remove the stud and the inner seal by pressing the stud down into the valve and out the end. 4. Remove the outer seal. 5. Remove the inner seat. *To re-assemble, do these steps in reverse with the new parts. © 2021 Staheli West...
Page 176: Test 1005: Hpls Calibration
HPLS. Loosen the set screw with a 5/64” Allen key. Adjust the HPLS trip point by rotating the nut: Clockwise to increase psi. Repeat steps until trip point is ±0.25 psi of the target. © 2021 Staheli West...
Page 177: Test 1006: Opls Calibration
OPLS. Loosen the set screw with a 5/64” Allen key. Adjust the OPLS trip point by rotating the nut: Clockwise to increase psi. Repeat steps until trip point is ±0.25 psi of the target. © 2021 Staheli West...
Page 178: Test 1007: Burner Tune
Press to deselect the Low Fire louver position. Press and wait for the burner to reach High Fire (boiler water temperature of 180° F or steam pressure of 5 psi) and repeat steps 3-5. © 2021 Staheli West...
Page 179: Test 1008: Canbus Address Setting
Use needle nose pliers to remove the weatherproofing Use a small flat head screwdriver to set the canbus plug. address. Actuator CAN Address Louver Actuator Water Purge Actuator Blowdown Actuator Steam Purge Actuator Top Steam Actuator Bottom Steam Actuator Feed Water Actuator © 2021 Staheli West...
Page 180: Test 1009: Boiler Water Level Sensor
The boiler water level should be at 0 and the low water If the water level does not match, replace the water should be open (shown above for sensor #2). level sensor. © 2021 Staheli West...
Page 181 50 Hour Maintenance..........177 250 Hour Maintenance / Yearly ......181 500 Hour Maintenance...........185 1000 Hour Maintenance ........187 2000 Hour Maintenance ........189 Winterize ..............191 Spring Start Up ............196 Flue Tube Cleaning ..........198 Maintenance Schedule ...........202 Notes..............203 © 2021 Staheli West...
Page 182: Daily Maintenance
Inspect gauges, sensors and sight glasses Purge steam through baler hardware nozzles to clear debris POST-OPERATION STEP(S) Purge steam through baler hardware nozzles to clear debris Remove crop debris from enclosed areas 1st OPERATION Check torque on wheel nuts (81 ft-lbs) © 2021 Staheli West...
Page 183 Re-install the supply water filter. Open the supply water isolation valve. Unscrew the supply water filter until water leaks out. Then screw the supply water filter back in. (This purges any trapped air in the lines. © 2021 Staheli West...
Page 184: Pre-Operation
Daily Maintenance (Pre-Operation) Open the boiler drain valve and drain water for 10 Grease the weasler shaft (about 20 pumps). seconds. Inspect gauges, sensors and sight glasses. Purge steam through baler hardware nozzles to clear debris. © 2021 Staheli West...
Page 185: Post-Operation
Daily Maintenance (Post-Operation) Purge steam through baler hardware nozzles to clear Remove crop debris from enclosed areas. debris. © 2021 Staheli West...
Page 186: Hour Maintenance
Purge steam through top front pigtail valves to clear the steam pressure sensor paths Grease PTO anti-rotating shields Grease PTO bearings Grease axles Inspect baler hardware 10-11 1st 50 HOUR MAINTENANCE Replace burner fuel filter (Napa 4006) (See 250 hour maintenance step 1) © 2021 Staheli West...
Page 187 Turn on the steamer and heat it up until it is under any potential hot spots on the boiler doors. Paint pressure. The steam purge will open when boiler is will bubble and change color if excessive heat has under pressure. occurred. © 2021 Staheli West...
Page 188 Grease the front PTO bearing and the bull pull hitch. Grease all the zerks on the grease block (located inside the rear door). Inspect all nozzles and ensure they are clean and Inspect steam hoses and ensure there are no kinks or functioning properly. holes. © 2021 Staheli West...
Page 190: Hour Maintenance / Yearly
Remove and clean burner gun nozzles Remove and clean airflow switch sensors and air lines Inspect boiler tubes for scale Rotate tires (front to rear) Check water purge system for blockages Clean water purge sensor Boiler Safety Test © 2021 Staheli West...
Page 191 Rotate tires front to rear. water tank. If crackling, the water purge system is working correctly. If not crackling, check the water purge path for blockages. (Depressurize boiler first) © 2021 Staheli West...
Page 192 250 Hour Maintenance / Yearly Water Purge Sensor Clean water purge sensor. Perform boiler safety test. (See safety section for Make sure boiler is not under pressure before instructions) removing water purge sensor. © 2021 Staheli West...
Page 194: Hour Maintenance
Perform 250 hour maintenance hour Clean boiler flue tubes (top and bottom as needed) Inspect boiler rear door “L” brackets for tightness (23 ft-lbs) Inspect boiler front smoke turn box insulation Check torque on wheel nuts (81 ft-lbs) © 2021 Staheli West...
Page 195 Clean the flue tubes if needed. (See Flue Tube Inspect boiler rear door “L” brackets for tightness. Cleaning) Tighten boiler rear door “L” brackets to 23 ft-lbs. Inspect the boiler front door insulation. Check torque on wheel nuts (81 ft-lbs). © 2021 Staheli West...
Page 196: 1000 Hour Maintenance
1000 Hour Maintenance Checklist EVERY 1000 HOURS STEP(S) See 50 Perform 50 hour maintenance hour See 250 Perform 250 hour maintenance hour See 500 Perform 500 hour maintenance hour Clean out water side of the boiler © 2021 Staheli West...
Page 197 Clean out the water side of the boiler. Remove all hand holes and camlocks. Pressure wash as much of the internals of the boiler as possible. Use a shop vac to vacuum everything out of the bottom of the boiler. © 2021 Staheli West...
Page 198: 2000 Hour Maintenance
EVERY 2000 HOURS STEP(S) See 50 Perform 50 hour maintenance hour See 250 Perform 250 hour maintenance hour See 500 Perform 500 hour maintenance hour See 1000 Perform 1000 hour maintenance hour Re-pack wheel hub bearings with grease © 2021 Staheli West...
Page 200: Winterize
• Anytime you plan to have the machine out of service for an extended time. Tools Needed: • Phillips Screwdriver • Crescent Wrench • Shop Vac • 7/16” End Wrench • Air Compressor FAILURE TO WINTERIZE WILL HURT YOUR WALLET © 2021 Staheli West...
Page 201 Caution: Steam will come out of steam hoses. Turn off the tractor and the valves will stay open. The Open the supply water valve to drain the supply tanks. next time the key is turned on the valves will close automatically. © 2021 Staheli West...
Page 202 Water from Remove the bottom feed pump plug with a 7/16” the cooler should drain out of the bottom of the feed wrench. water pump where the plug was removed. © 2021 Staheli West...
Page 203 Place sensors in an area that will not drop below 32° F during winter WAIT 1 DAY Remove hand hole. Take picture of tubes to see the Wait one day for the boiler to dry out. differences year to year. © 2021 Staheli West...
Page 204 Re-install the hand hole. valves. Turn the tractor key off. Re-install the supply water filter. Re-install the feed water pump plug. Put tie-down straps on flue exhaust caps to prevent water, birds, & rodents from entering the flue. © 2021 Staheli West...
Page 205: Spring Start Up
SAFETY PRECAUTIONS • Do not climb on machine to perform procedures. • Always use a ladder or other appropriate means, to reach upper components. Tools Needed: • Phillips Screwdriver • Crescent Wrench • 9/16” End Wrench © 2021 Staheli West...
Page 206 0-5 psi Re-install the steam pressure sensor. Re-install the supply water level sensor. Feed Pump Protection 0-30 psi Re-install the feed pump protection sensor. Test the pressure relief valve by lifting up the lever fully several times. © 2021 Staheli West...
Page 207: Flue Tube Cleaning
Remove these 12 nuts with a 9/16” wrench/socket. Remove these 6 nuts and bolts with a 1/2” wrench/ socket. Remove the 4 shields. Remove the 4 remaining nuts on the front door with a 9/16” wrench/socket, and remove the door. © 2021 Staheli West...
Page 208 Clean the tubes one column at a time. Clean the bottom tube first, then insert the shop vac. With the shop vac running, clean each tube above until the column is clean (keep the shop running and inserted in the bottom tube). *Clean vacuum filter as needed. © 2021 Staheli West...
Page 209 Re-install the front boiler door. Tighten the 4 nuts shown above. Re-install the 4 shields. Re-install these 6 nuts and bolts with a 1/2” wrench/ socket. Re-install the hood. Install these bolts with a 3/4” Re-install these 12 nuts with a 9/16” wrench/socket. wrench/socket. © 2021 Staheli West...
Page 211: Maintenance Schedule
Grease PTO anti-rotating shields Grease PTO bearings Grease/Lube Grease bull pull hitch Grease axles Re-pack wheel hub bearings with grease (1st) Check torque on wheel nuts (81 ft-lbs) Frame/Axles Rotate tires (front to rear) Other Inspect baler hardware © 2021 Staheli West...

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