Wacker Neuson HI 770XHD Operator'S Manual Download Page 91

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HI 770XHD

Genset Maintenance

Check fuel injection
nozzle and pressure

Check injection pump.

Change radiator cool-
ant.

Replace battery.

Replace radiator hoses
and clamps.

Replace fuel pipes and
clamp bands.

Replace air intake
hose.

Task

Interval

Hours

Years

Daily

100

200

400

500

800

1500

3000

* More often in dusty conditions.

See Kubota dealer for service.

Summary of Contents for HI 770XHD

Page 1: ...5200003388 04 0212 5 2 0 0 0 0 3 3 8 8 Operator s Manual IDF Heater HI 770XHD EN...

Page 2: ...distribution not authorized by Wacker Neuson Production Americas LLC represents an infringement of valid copyrights Violators will be prosecuted Trademarks All trademarks referenced in this manual are...

Page 3: ...d and observe all instructions described in this manual Wacker Neuson expressly reserves the right to make technical modifications even without notice which improve the performance or safety standards...

Page 4: ...acker Neuson Unapproved parts attachments and modifications are those that do not meet the approved criteria Unapproved parts attachments or modifications may have the following consequences Serious i...

Page 5: ...and Transporting 28 3 1 Lifting the Machine 28 3 2 Preparing the Machine for Transport on a Truck or Trailer 29 3 3 Transporting the Machine on a Truck or Trailer 30 3 4 Before Towing Checklist 31 3 5...

Page 6: ...ombustion Head Assembly 63 6 6 Recommended Burner Nozzles 65 6 7 Replacing the Burner Nozzle 66 6 8 Checking and Adjusting the Electrode Position 68 6 9 Checking Adjusting the Burner Air Band 69 6 10...

Page 7: ...he Radiator 97 8 7 Servicing the Air Cleaner and the Air Filter 99 9 Basic Troubleshooting 100 10 Technical Data 102 10 1 Machine 102 10 2 Dimensions 103 11 Schematics 104 11 1 AC Circuit 104 11 2 Wir...

Page 8: ...Table of Contents HI 770XHD wc_bo5200003388_04TOC fm 8...

Page 9: ...personal hazards f Obey all safety messages that follow this symbol DANGER DANGER indicates a hazardous situation which if not avoided will result in death or serious injury f To avoid death or serio...

Page 10: ...er purpose could permanently damage the machine or seriously injure the operator or other persons on the work site Machine damage caused by misuse is not covered under warranty This machine has been d...

Page 11: ...devices The machine must not be accessed or operated by children people impaired by alcohol or drugs Application area Be aware of the application area Keep unauthorized personnel children and pets awa...

Page 12: ...n the machine on a firm noncombustible level surface Keep the area immediately surrounding and underneath the machine clean neat and free of debris and combustible materials Keep the area above the ma...

Page 13: ...uel tank in a well ventilated area When using the machine Do not fill or drain the fuel tank near an open flame while smoking or while the machine is running Do not smoke when refueling the machine Do...

Page 14: ...rs and adjustments shall be completed by a qualified technician Turn off the machine before performing maintenance or making repairs Remain aware of the machine s moving parts Keep hands feet and loos...

Page 15: ...ition before servicing or maintaining the machine Tie back long hair Remove all jewelry including rings Maintenance guidelines When maintaining the machine Keep the fuel lines in good condition and pr...

Page 16: ...and the fuel tank for leaks and cracks before starting the engine Clean the genset of any spilled fuel DANGER Carbon monoxide Using a generator indoors CAN KILL YOU IN MINUTES Gen erator exhaust cont...

Page 17: ...r is hot Refueling safety When adding fuel to the fuel tank Do not smoke Do not refuel a hot or running engine Do not use diesel fuel that is mixed with gasoline or alcohol When adding fuel to the fue...

Page 18: ...operly inflated Only tow the machine when all trailer lights are functioning correctly Only tow the machine when the trailer s safety chains are connected to the towing vehicle in a crisscross pattern...

Page 19: ...or hold the machine safely See section Technical Data for machine weight Remain aware of the location of other people when lifting the machine Only use the lifting points and tie downs described in th...

Page 20: ...Labels HI 770XHD 20 wc_si000622gb fm 2 Labels 2 1 Label Locations 135 116 118 140 48 52 48 211 80 53 137 137 64 118 136 46 164 137 167 166 999 64 135 118 118 995 116 209 204 wc_gr008639...

Page 21: ...ormation for the machine 26 Machine rating label This label indicates rat ing information for the machine For machines powered by the generator Use a 50 50 blend of 2 diesel and 1 diesel plus additive...

Page 22: ...PLUGS lamp should illuminate Hold key switch in this position to heat glow plugs according to guidelines below If ambient temperatures are Above 40 F Hold for 10 seconds Between 20 40 F Hold for 30 se...

Page 23: ...desired output temperature 8 Turn BLOWER switch ON 9 Turn BURNER switch ON Burner motor will start after 5 second delay and fuel will be ignited after 6 second purge NOTE If the machine has run out of...

Page 24: ...tion marker 135 Forklift lift point 136 CAUTION This machine uses diesel fuel 137 NOTICE Lift point Attach lifting device in this location 140 CAUTION Hot surface hazard DIESEL CAUTION VORSICHT PRECAU...

Page 25: ...label informs the user of the location and rating of the generator auxiliary power output receptacle 167 Power input 120VAC 15A maximum This label informs the user of the location and rating of the i...

Page 26: ...is label indicates rat ing information for the machine WARNING WARNUNG ADVERTENCIA AVERTISSEMENT 173200 5200002911 Never operate in an explosive environment or near flammable vapors fuels or combustib...

Page 27: ...he operator should contact local fire agencies for laws or regulations relating to fire prevention requirements WARNING Operation of This Equipment May Create Sparks That Can Start Fires Around Dry Ve...

Page 28: ...abeled locations b and skip to step 3 2 Attach the other end of the chains to the lifting equipment 3 Lift the machine a small distance 4 Check for stability If necessary lower the machine reposition...

Page 29: ...hocked during the loading process Check that the transport vehicle or trailer is clean and free of grease oil ice and other loose material If the machine is mounted to a trailer check that the jacksta...

Page 30: ...w to transport on a flat bed truck or trailer 1 Move the machine onto the flat bed truck using properly rated ramps or docks or by lifting it 2 Install a support a under the trailer tongue 3 Remove th...

Page 31: ...fresh grease applied to it Wheels Check that all lug nuts are in place and are properly torqued Check the tread wear of the tires Check that the tires are inflated to the proper pressure Trailer oper...

Page 32: ...d fuel spillage 4 Complete the Before Towing Checklist See topic Before Towing Checklist 5 Connect the machine to the tow vehicle 6 Connect the safety chains a to the tow vehicle in a crisscross patte...

Page 33: ...e machine trailer to the tow vehicle 2 Disconnect the trailer wiring plug a from the tow vehicle 3 Pull the breakaway pin b out of the brake switch c to activate the brakes and attempt to tow the mach...

Page 34: ...or recharge the breakaway battery 6 If 12 14 VDC was measured but the brakes did not function there is a wiring or mechanical fault with the brakes Repair any faults before towing 7 If the brakes fun...

Page 35: ...c Ref Description Ref Description a Heater exhaust g Air output with duct adapter b Burner access door h Emergency stop switch c Genset exhaust i Generator auxiliary power output d Genset compartment...

Page 36: ...and water separator i Fuel gauge c Snap disc switch 210 F manual reset j Burner ignition transformer d Burner fuel pressure gauge k Burner primary control e Burner l Burner blower motor f Generator f...

Page 37: ...ents Ref Description Ref Description a 120 208VAC control panel f Marathon 3 phase generator b 12 VDC control panel g Kubota engine oil reservoir c Battery shut off switch h Blower d Battery i Kubota...

Page 38: ...ch Switches electric power ON and OFF to the burner e Temperature control Allows the user to control the target appli cation temperature Displays the setpoint and actual output air temperatures f Burn...

Page 39: ...r s low oil pressure safety circuit in order to start the generator k Ignition switch Allows the user to start the generator See section Starting the Generator Engine for more information l Exhaust fa...

Page 40: ...splay SV Displays desired temperature of the dis charge air b Process value display PV Displays actual temperature of the discharge air c C1 indicator Indicates a call for heat d Temperature unit indi...

Page 41: ...12 gauge extension cords for lengths up to 15 m 50 ft Use 10 gauge extension cords for lengths up to 30 m 100 ft Procedure 1 Place the outlet breaker c in the ON position 2 Connect the 120VAC supply...

Page 42: ...machine 4 9 2 Connect grounding cable if necessary 4 10 3 Perform Pre Starting checks 4 11 a Refuel the machine 4 12 4 13 b Verify correct duct adapter is installed 5 1 c Install heater ducting 4 14...

Page 43: ...t safety standards UL 2034 IAS 6 96 or CSA 6 19 01 Test the CO alarm batteries monthly This procedure continues on the next page DANGER Asphyxiation hazard Exhaust gas from the engine and the burner c...

Page 44: ...l of the machine s access doors panels may be accessed So that power cords and ducting do not pose tripping hazards and so that the power cords and ducting cannot be damaged by machines or other equip...

Page 45: ...machine when necessary to comply with the National Electrical Code and other federal state and local regulations For grounding requirements in your area consult with a qualified electrician electrical...

Page 46: ...rify that the tank is filled with the correct type of fuel See topic Recommended Fuel 2 Control switches all must be Off 3 Duct adapters verify that the duct adapters are properly installed for the de...

Page 47: ...ype of biodiesel fuel in this machine Fuel Blend Guide Lowest expected ambient temperature F C Generator powered Below 5 15 50 50 blend of 2 diesel and 1 diesel plus additives OR 50 50 blend 2 diesel...

Page 48: ...3 Fill the tank with the appropriate grade of fuel for the weather conditions until the gauge b reads full Leave room within the tank for possible fuel expansion 4 Reinstall the fuel cap 5 Close the...

Page 49: ...pecified in Technical Data Requirements Machine shut down and cooled Machine properly positioned Procedure To install the ducts carry out the following procedure 1 Open the clamps a 2 Slide the duct b...

Page 50: ...ultaneously press and hold the low oil pressure override button d and turn and hold the ignition switch b to the START position NOTICE Do not crank the generator engine for more than 20 seconds Do not...

Page 51: ...that the volt and frequency meters d and e are within nominal operational values Note If the voltage and frequency values are not satisifactory diagnose and rectify the problem before continuing 6 Mov...

Page 52: ...urner ON OFF switch h to the ON position Note The burner will perform a series of automated safety checks and will ignite after approximately 11 seconds Result The machine is now running WARNING Explo...

Page 53: ...Ambient air Running the machine in this mode pressurizes the heated space Air from the structure being heated This is done by connecting ducting from the structure to the air inlet port Running the ma...

Page 54: ...e the burner ON OFF switch a to the OFF position 2 Wait until the temperature controller b reads 100 F 38 C or less NOTICE Do not turn off the blower until the machine cools below 100 F 38 C 3 When th...

Page 55: ...below to shut down the generator and the DC circuit NOTICE Allow the generator to run approximately 1 minute with no load before shutting it down 1 Turn the ignition switch e to the OFF position 2 Tu...

Page 56: ...shutdown Procedure Perform the procedure below to stop the machine and lock out all power to the controls during an emergency 1 Press the emergency stop push button a 2 Place all circuit breakers and...

Page 57: ...ker Neuson distributor Configuration These accessories offer three options for configuring the duct work on the machine See sections Removing and Installing a Duct Adapter for more information Ref Ite...

Page 58: ...o install a duct adapter 1 Remove the 12 bolts a and the currently installed duct adapter b 2 Install a new duct adapter and replace the bolts a Result The procedure to remove and install a duct adapt...

Page 59: ...ng any of the duct openings constricts the air flow through the machine and may cause a high temperature shut down fault MODEL RETURN DUCTING SUPPLY DUCTING Return duct adapter Maximum number of 25 ft...

Page 60: ...burner performance is in question Tools required The following tools are required to adjust the burner High quality combustion analyzer Smoke spot tester General hand tools Mandates Adjustments made s...

Page 61: ...type of biodiesel fuel in this machine Fuel Blend Guide Lowest expected ambient temperature F C Generator powered Below 5 15 50 50 blend of 2 diesel and 1 diesel plus additives OR 50 50 blend 2 diesel...

Page 62: ...ner to function properly Components Ref Description Ref Description a Burner flange gasket i Head setting adjusting screw b Ignition transformer j Blower wheel c Fuel pump k Blower motor d Fuel shut o...

Page 63: ...ocedure below to remove the combustion head 1 Remove the screw a that secures the ignitior cover b to the top of the burner and swing open the ignitor cover 2 Loosen the fuel line coupling c at the el...

Page 64: ...maging the assembly do not force the combustion head assembly into the flame tube 1 Carefully insert the combustion head assembly d into the flame tube 2 Seat the oil tube bracket into the slot on the...

Page 65: ...g illustrates the meaning of the common numbers found on burner nozzles Parameters Ref Parameter Description a Flow rating Flow rating is determined at 100 psi using 2 oil b Spray angle Angle of the s...

Page 66: ...en to replace Once per year if necessary If the burner is not firing If the burner performance is in question NOTICE Improper handling of the burner parts may cause damage Use caution when handling th...

Page 67: ...zzle by placing a wrench on the nozzle adapter d and the nozzle c 5 Reinstall the flame retention ring b and tighten the screw a 6 Replace the combustion head assembly See section Removing and Install...

Page 68: ...e burner is not firing properly Checking To check the electrode position measure the following distances between tips a electrode to nozzle b electrode tip to nozzle center line c Refer to the table b...

Page 69: ...r Air Band Procedure Perform the procedure below to adjust the burner air band 1 Loosen the air band locking screw a 2 Rotate the air band until the desired percentage of opening is attained 3 Tighten...

Page 70: ...cking Adjusting the Burner Head Procedure Perform the procedure below to adjust the burner head 1 Turn the head adjustment screw a clockwise to decrease the setting and counterclockwise to increase th...

Page 71: ...Fuel pressure range 125 150 psi Procedure Perform the procedure below to set fuel pressure 1 Start the machine 2 Observe the fuel pressure gauge b 3 Turn the adjusting screw a clockwise to increase pr...

Page 72: ...uld be taken as the heater warms The final sample should be taken just before the heater reaches 71 C 160 F Analyzing the O2 content 2 Follow the combustion analyzer manufacturer s instructions and th...

Page 73: ...Task Interval Daily 6 Months Yearly Machine Check fuel level 3 Clean the air intake area with compressed air As needed Clean the machine interior Replace the burner fuel fil ter with priming bulb Ins...

Page 74: ...lubricate the drive bearings 1 Remove the blower access cover a 2 Lubricate the pillow block bearings b on both ends of the drive shaft Use high quality lithium based grease NLGI Grade 2 consistency...

Page 75: ...e shut down and cooled Procedure Perform the procedure below to clean the blower motor 1 Remove the blower access cover a 2 Use a dry cloth to clean the air intake grate c on the blower motor 3 Reinst...

Page 76: ...proper tension 1 Remove the blower access cover a 2 Inspect the drive belts e for wear Replace if necessary 3 Measure the belt deflection If necessary adjust the tension using the L shaped bolts f No...

Page 77: ...e below to check the pulleys for wear 1 Remove the blower access cover a 2 Remove tension from the drive belts using the L shaped bolts f 3 Remove the drive belts from the pulleys 4 Inspect the pulley...

Page 78: ...d in accordance with local environmental protection laws 1 To drain water from the bowl open the valve a 2 To change the filter c a Unscrew the bowl b b Unscrew the filter cartridge c c Apply a film o...

Page 79: ...achine has been transported or towed over extremely rough roads or ter rain The machine towing vehicle has been involved in an accident The machine has been dropped There is visible damage to the heat...

Page 80: ...exchanger 1 Remove the burner p and position it as shown 2 Remove the outer exhaust duct a 3 Remove the inner exhaust duct z 4 Remove the seal plate b 5 Remove two corner lifting brackets c and two s...

Page 81: ...ness back into the machine 8 Remove the fasteners g that hold the support staffs to the roof There are two support staffs remove the fasteners for both Loosen the clamp h that holds the tail pipe to t...

Page 82: ...side roof panel to the machine Remove the fasteners from both the front and back of the machine 12 Tilt the exchanger side roof panel up so that the two roof panels may be separated from each other l...

Page 83: ...e piece of cladding insulation blanket r 17 Remove the screws that hold the front piece of cladding s and tilt it forward as shown This allows access to the inner chamber This procedure continues on t...

Page 84: ...chamber for cracks or separations Inspect the all welded areas Use an inspection mirror if necessary It may be necessary to clean the areas of inspection with a stainless steel wire brush prior to in...

Page 85: ...any of the following conditions exist Contact Wacker Neuson Product Support for assistance Cracks or separations are discovered in the heat exchanger Soot is visible on the exterior air side of the h...

Page 86: ...and fill any old screw holes with silicone 3 Reinstall the side q top r and front s cladding insulation blankets 4 Reinstall the rear side panel n and the front side panel o 5 Reinstall the roof panel...

Page 87: ...abilizer is acceptable 2 Allow heater to cool sufficiently Cover the chimney and the burner with plastic wrap or other waterproof material This will prevent corrosive moisture build up and blockages c...

Page 88: ...with the machine powered up Item Task Machine exterior Clean all outside surfaces Heater and burner Remove protective coverings from chimney and burner Remove any carbon build up from the heater and...

Page 89: ...to improve cold weather starting Precautions Observe the following precautions to prevent serious damage to the electrical system Do not disconnect the battery while the machine is running Do not atte...

Page 90: ...3 Check fuel water sepa rator drain water as needed 3 Check fuel hoses and clamps 3 Clean air cleaner ele ment 3 Check fan belt tension 3 Check radiator hoses and clamps 3 Check intake air hose 3 Repl...

Page 91: ...eck injection pump 3 Change radiator cool ant 3 Replace battery 3 Replace radiator hoses and clamps 3 Replace fuel pipes and clamp bands 3 Replace air intake hose 3 Task Interval Hours Years Daily 50...

Page 92: ...evel is low remove the filler plug 2 and add oil through the filler opening until the level is within the range on the end of the dipstick NOTICE Do not operate a diesel engine when it is overfilled w...

Page 93: ...quid in accordance with local environmental protection laws 1 To drain water from the bowl open the valve a 2 To change the filter c a Unscrew the bowl b b Unscrew the filter cartridge c c Apply a fil...

Page 94: ...al protection laws 1 Operate the genset until warm then stop the engine 2 Remove the plug from the end of the drain valve a 3 Connect a drain hose to the drain valve This procedure continues on the ne...

Page 95: ...in accordance with local environmental protection laws 7 Clean the oil filter mounting surface Filling 1 Apply a thin coat of clean oil to the gasket of the new oil filters 2 Thread the oil filters o...

Page 96: ...ic sheet and a container under the machine to collect any liquid which drains off Dispose of this liquid in accordance with local environmental protection laws 1 Unscrew the fuel filter a Dispose of u...

Page 97: ...engine Allow it to cool at least 30 minutes after stopping 2 Open the genset access panel and locate the reserve tank 1 3 Check the level of coolant within the reserve tank If the level of coolant is...

Page 98: ...tor cap b and allow any residual pressure to escape then remove the cap 5 Connect separate drain hoses to the engine drain valve c and to the radiator drain valve d With an appropriate container s rea...

Page 99: ...mpressed air Blow the air through the air filter from the inside to the outside 5 Hold the air filter up to the light or pass a lamp through the middle to check the condition of the air filter Replace...

Page 100: ...rn Replace the burner nozzle The electrodes are malfunc tioning Replace the electrodes The cadmium cell is malfunc tioning Replace the cadmium cell The burner primary control is malfunctioning Replace...

Page 101: ...y tightened Adjust belt tension Over or under voltage Check power supply Fan inoperative Circuit breaker tripped Reset circuit breaker Loose or disconnected wiring Check wiring and repair as needed Ma...

Page 102: ...g C F 40 40 Performance Data Fuel input low firing rate BTU 430 000 Fuel input high firing rate BTU 770 000 Heat ouput low firing rate BTU 322 000 Heat output high firing rate BTU 578 000 Heater effic...

Page 103: ...HI 770XHD Technical Data wc_td000474gb fm 103 10 2 Dimensions Trailer GVWR kg lb 3421 7543 GAWR kg lb 3175 7000 Wheel code 16 X 6 K Tire code LT 235 85R16 G Tire pressure kPa psi 758 110...

Page 104: ...wc_tx001887gb fm 104 Schematics HI 770XHD 11 Schematics 11 1 AC Circuit...

Page 105: ...nnection box b Ground bar c Circuit breaker main 30A d Blower ON OFF switch e Blower 208V 3 hp f Circuit breaker burner 20A g Temperature controller h Thermocouple i Circuit breaker outlet 15A j Snap...

Page 106: ...wc_tx001887gb fm 106 Schematics HI 770XHD 11 4 DC Circuit...

Page 107: ...Ignition switch g Fuse 15A h By pass switch i Emergency stop button j Glow plug indicator light k Glow plugs l Oil pressure switch m Coolant switch n Fuel pump o Fuel solenoid p Hour meter q Running...

Page 108: ...wc_tx001887gb fm 108 Schematics HI 770XHD 11 6 Trailer Lights and Brakes Wiring Diagram wc_gr008734 a1 a2 b1 c1 b2 c2 d1 d2 f e1 e2 g j h i R W L Br Br G d1 d2 f e1 e2 g c1 b1 a1 a2 c2 b2...

Page 109: ...amber b2 Left side miniature light amber c1 Right side fender light amber c2 Left side fender light amber d1 Right rear fender light red d2 Left rear fender light red e1 Right side stop and tail light...

Page 110: ...for specific components The designations are as follows Note The colors used on your vehicle s plug may vary from those used in the trailer junction box CHARGER BREAKAWAY SWITCH B black R red G green...

Page 111: ......

Page 112: ...cker Neuson Production Americas LLC N92W15000 Anthony Ave Menomonee Falls WI 53051 Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 Wacker Neuson Limited Room 1701 03 1717 20 17 F Tower 1 Grand Cent...

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