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Copyright notice

© Copyright 201

9

 by Wacker Neuson Production Americas LLC

All rights, including copying and distribution rights, are reserved.

This publication may be photocopied by the original purchaser of the 
machine. Any other type of reproduction is prohibited without express 
written permission from Wacker Neuson Production Americas LLC.

Any type of reproduction or distribution not authorized by Wacker 
Neuson Production Americas LLC represents an infringement of valid 
copyrights. Violators will be prosecuted. 

Trademarks

All trademarks referenced in this manual are the property of their 
respective owners.

Manufacturer

Wacker Neuson Production Americas LLC

N92W15000 Anthony Avenue

Menomonee Falls, WI 53051 U.S.A.

Tel: (262) 255-0500 · Fax: (262) 255-0550 · Tel: (800) 770-0957

www.wackerneuson.com

Original instructions

This Operator’s Manual presents the original instructions. The original 
language of this Operator’s Manual is American English.

Summary of Contents for HI400HD D

Page 1: ...Operator s Manual Indirect Fired Air Heaters HI400HD D HI400HD G Type Document Date Revision Language HI400HD D HI400HD G 5000192824 0419 12 EN 5 0 0 0 1 9 2 8 2 4 ...

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 the property of their respective owners Manufacturer Wacker Neuson Production Americas LLC N92W15000 Anthony Avenue Menomonee Falls WI 53051 U S A Tel 262 255 0500 Fax 262 255 0550 Tel 800 770 0957 ...

Page 3: ...ING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm WARNING Cancer and Reproductive Harm www P65Warnings ca gov WARNING Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defects or ot...

Page 4: ...CALIFORNIA Proposition 65 Warning Proposition 65 Warning 4 wc_tx004643en fm Notes ...

Page 5: ... use of this machine WARNING Failure to comply with the precautions and instructions provided with this machine can result in death serious injury and property loss or damage from fire explosion burns asphyxiation carbon monoxide poisoning and or electric shock Before using the machine read and understand all precautions and instructions that have been provided Follow them carefully Only persons w...

Page 6: ...requesting parts or service for this machine Machine documentation From this point forward in this documentation Wacker Neuson Production Americas LLC will be referred to as Wacker Neuson Keep a copy of the Operator s Manual with the machine at all times For spare parts information please see your Wacker Neuson Dealer or visit the Wacker Neuson website at http www wackerneuson com When ordering pa...

Page 7: ...efer to Wacker Neuson factory installed components Your machine may vary depending on the requirements of your specific region Manufacturer s approval This manual contains references to approved parts attachments and modifications The following definitions apply Approved parts or attachments are those either manufactured or provided by Wacker Neuson Approved modifications are those performed by an...

Page 8: ...Foreword HI400HD D HD G 8 ghi_tx001460gb_FM10 fm ...

Page 9: ...t Use 29 4 2 Installing the Axle and Wheels 29 4 3 Installing the Front Duct Adapter 30 4 4 Blower Duct Heater Option 31 4 5 Installing the Rear Duct Adapter Optional 32 4 6 Control and Component Locations 33 4 7 Adjusting the Handle Height 34 4 8 Positioning the Machine 35 4 9 Electrical and Grounding 36 4 10 Control Panel Oil Burner D Models 37 4 11 Recommended Fuels and Fuel Blending Guide 38 4...

Page 10: ...he Burner 60 6 3 Setting up the Burner 61 6 4 Adjusting the Gas Pressure G Models 63 6 5 Inspecting the Oil Burner Electrodes D models 67 6 6 Checking and Changing the Burner Nozzle D models 68 6 7 Checking and Adjusting the Air Damper 69 6 8 Checking and Adjusting the Fuel Pressure 70 7 Maintenance 73 7 1 Periodic Maintenance Schedule 73 7 2 Inspecting the Heat Exchanger 74 7 3 Changing the Fuel ...

Page 11: ... fm 11 HI400HD D HD G Table of Contents 9 Technical Data 84 9 1 Machine 84 10 Schematics 86 10 1 HI400HD D 86 10 2 Components 87 10 3 HI400HD G 2014 88 10 4 Components 2014 89 10 5 HI400HD G 2015 90 10 6 Components 2015 91 ...

Page 12: ...12 wc_bo5000192824_11TOC fm HI400HD D HD G Table of Contents ...

Page 13: ...o potential personal hazards 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 To avoid death or serious injury from this type of hazard obey all safety messages that follow this signal word WARNING WARNING indicates a hazardous situation which if not avoided could result in death or serious in...

Page 14: ...r 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 Do not use this machine indoors without proper exhaust venting designed for indoor use which meets all applicable regulations This machine has been designed and built in accordance with the latest global safety standards It ...

Page 15: ...nnel children and pets away from the machine Remain aware of changing positions and the movement of other equipment and personnel in the application area job site Identify whether special hazards exist in the application area such as toxic gases or unstable ground conditions and take appropriate action to eliminate the special hazards before using the machine Do not operate the machine in areas th...

Page 16: ...s Hearing protection Safety toed footwear Machine condition Only operate the machine when The heat exchanger is in proper working order All safety devices and guards are in place and in working order All controls operate correctly The machine is set up correctly according to the instructions in the Operator s Manual The machine is clean The machine s labels are legible When operating the machine D...

Page 17: ...ollow all instructions in the Operation chapter Important points to note are Position the machine correctly before each use Provide proper venting for both indoor and outdoor use Do not operate the machine with exterior panels removed Disconnect all electrical power from the machine before opening doors or removing panels Check the gas lines and connections for leaks WARNING Gas leaks can cause ex...

Page 18: ...ty state or province in which the machine is being installed to work with natural gas or Liquid Petroleum LP 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 DANGER Exhaust gas from the burner and generator if equipped contains carbon monoxide a deadly poison Exposure to carbon monoxid...

Page 19: ...rs and adjustments shall be completed by a qualified technician Turn off the machine before performing maintenance or making repairs Machine modifications When servicing or maintaining the machine Use only accessories attachments that are approved by Wacker Neuson Do not defeat safety devices Do not modify the machine without the express written approval of Wacker Neuson Replacing parts and labels...

Page 20: ...e machine is not being operated Close the fuel valve on engines equipped with one when the machine is not being operated Ensure that the machine will not tip over roll slide or fall when not being operated Store the machine properly when it is not being used The machine should be stored in a clean location out of the reach of children Licensing training Only qualified personnel who possess the pro...

Page 21: ...ghi_si000469gb_FM10 fm 21 HI400HD D HD G Labels 2 Labels 2 1 Label Locations HI400 HD D a c f h o f q e c d p b g x j wc_gr011675 ...

Page 22: ...ghi_si000469gb_FM10 fm 22 Labels HI400HD D HD G 2 2 Label Locations HI400 HD G f m h w b g g s c c u q e c p t x j wc_gr011676 ...

Page 23: ...point f WARNING Hot surface g WARNING Entanglement hazard Rotating machinery Do not reach inside machine when engine is running h WARNING Using a heater indoors can kill you in minutes Heater exhaust contains carbon monoxide This is a poison you cannot see or smell During indoor operation vent exhaust gas outdoors Refer to Operator s Manual ...

Page 24: ...nd Federal authorities Failure to heed this warning may result in an explosion and or fire causing property damage personal injury or death o Safety instruction label for diesel fuelled heaters p DIRECTIONS FOR OPERATION 1 Connect the machine to 120V power sup ply using a 12 3 x 50 foot max 10 13 x 100 foot max extension cord 2 Wait 20 30 minutes to allow the oil filter to pre heat the fuel 3 Turn...

Page 25: ...FM10 fm 25 HI400HD D HD G Labels r Gas shut off valve s Gas selector valve Propane Gas Position Natural Gas Position Lock valve in position after selection t Electrical grounding instructions w General usage warnings ...

Page 26: ... the Operator s Manual for more information If three consecutive attempts to reset the machine are unsuccessful then troubleshoot the heating system for the root cause s of the lockout Make necessary repairs or adjustments to ensure a safe start condition Ensure that the heat exchanger is free of oil and oil vapors before starting or resetting the burner ...

Page 27: ...ghi_si000469gb_FM10 fm 27 HI400HD D HD G Labels Fork lift pocket ...

Page 28: ...penings on the machine to avoid infiltration from road debris and dust When using an aerial lifting rig use the designated lifting point on top of the machine Use the designated fork pockets when transporting the machine with a fork lift Use the manual transport handle when relocating the machine within the job site When tying down the machine route tie down straps or chains through the lower fram...

Page 29: ... 5 Add fluids as needed and applicable including fuel engine oil and battery acid 6 Move the machine to its operating location 4 2 Installing the Axle and Wheels Overview The axle and wheels are shipped loose with the machine and must be installed by the customer Procedure Perform the procedure below to install the axle and wheels 1 Lift the machine using appropriate lifting gear 2 Slide the axle ...

Page 30: ...ocedure below to install the front duct adapter and thermostat probe 1 The thermostat probe a is temporarily mounted on a disposable bracket b inside the machine shell Remove and set aside the mounting screw c to disconnect the bracket from the machine shell 2 Remove the screw fastening the thermostat probe to the disposable bracket and discard the bracket Temporarily rest the thermostat probe ins...

Page 31: ... with integral clamps Phillips screwdriver or nut driver Flat screwdriver Procedure Perform the procedure below to install the blower duct 1 Remove the square plate from the bottom of the front duct adapter Replace the square plate with the 10 cm 4 in snorkel a and tighten the screws securely 2 Install the front duct adapter according to the instructions provided in Installing the Front Duct Adapt...

Page 32: ...djusting knobs a on the handle 2 Grasp the handgrips b and slide the handle down to the lowest detent position in the handle slots 3 Pull the handle away from the fan guard f 4 Remove the fan guard There are four screws that secure the fan guard 5 Align the four threaded mounting holes e on the duct adapter with the corresponding holes on the machine shell 6 Use the fan guard screws to fasten the ...

Page 33: ...achine components HI400HD G a k Ref Description Ref Description a Exhaust flue g Access cover b Control panel h Fuel filter D units c Manual transport handle i Gas train G units only d Fuel fill location D units only j Fork pockets e Lift brackets k Manual holder f Air inlet and fan guard ...

Page 34: ...sted to suit the operator s preference Procedure Perform the procedure below to adjust the handle height 1 Loosen but do not remove the two adjusting knobs a on the handle 2 Grasp the handgrips b and slide the handle up or down to one of the three detent positions in the handle slots 3 When the handle is in the desired position tighten the two adjusting knobs wc_gr007767 a a b ...

Page 35: ...ons The machine must be located a safe distance from any other structures vehicles materials or other combustible surfaces The following proximity restrictions apply for all machine installations 20 ft 6 m to air outlet 3 ft 1 m to air inlet and sides 5 ft 1 5 m to top 20 ft 6 m from outlet to external fuel container Note Graphic is representational Your machine may vary DANGER Carbon monoxide Exh...

Page 36: ... Code ANSI NFPA 70 or the CSA C22 1 Canadian Electrical Code Part 1 Connecting power Perform the procedure below to connect power to the machine 1 Verify that the operation mode switch is in the OFF 0 position 2 Connect the main power cord to a properly rated power source Note If the ambient temperature is below freezing wait 10 30 minutes before proceeding WARNING Fire and electric shock hazards ...

Page 37: ... Mode switch on off on See topic Starting the Machine e Power indicator c Remote thermostat receptacle f Power cord Symbol Meaning function Symbol Meaning function Push the button to reset the machine when a burner fault occurs On Continuous heat mode See topic Starting the Machine On Remote thermostat mode See topic Starting the Machine Remote thermostat connection point Low fire mode See topic R...

Page 38: ...th an equivalent as specified on the machine label Fuel Blend Guide Lowest expected ambient temperature F C Generator powered Shore powered Below 5 15 50 50 blend of 2 diesel and 1 diesel plus additives OR 50 50 blend of 2 diesel and K1 kerosene plus additives 100 1 diesel plus additives OR 100 K1 kerosene plus additives 5 to 25 15 to 4 70 30 blend of 2 diesel and 1 diesel plus additives OR 70 30 ...

Page 39: ...Run the machine as normal RESET Ref Description Ref Description a Operating status indicator and reset button dual function e Power indicator b Mode switch on off on See topic Starting the Machine f Power cord c Remote thermostat receptacle g Polarity indicator illuminates when polarity of power supply is incorrect d Burner indicator Symbol Meaning function Symbol Meaning function Push the button ...

Page 40: ...ze and capacity of gas cylinders shall be properly dimensioned according to the gas flow in Technical Data The cylinder supply system shall be arranged to provide for vapor withdrawal from the operating cylinder After connecting the machine to the gas cylinder open the supply tap and check the supply pipe and fittings for gas leaks Only use foam soap or an approved leak detector The gas shall be t...

Page 41: ...ry pressure regulator ensures a steady flow of LP to the burner A regulator is especially valuable when the gas supply pressure is inconsistent Note Gas piping pressure regulators and fittings are not included with this heater and must be provided by the customer wc_gr015340 a WARNING Extreme fire and explosion hazard Only a licensed professional gas technician shall perform installation fuel supp...

Page 42: ... selector valve on the gas train allows you to convert the machine from natural gas to LP as job site conditions require Procedure Perform the procedure below to change the type of gas 1 Ensure that the gas shutoff valve is closed 2 Loosen the screw a on the gas selector valve 3 Turn the handle to the desired position 4 Tighten the screw 5 Open the gas shutoff valve wc_gr015341 a ...

Page 43: ...ree from obstruction Ensure that there are no bulky objects or sheets covers near or on the machine Routing the vent piping Route the venting pipes in a manner that avoids flammable materials Route the venting pipes in a manner that avoids contact with people Sufficient draft shall be created to assure safe and proper operation of the machine minimum 0 05 in w c Avoid any 90 elbows or bends in at ...

Page 44: ...1462gb_FM10 fm 44 Operation HI400HD D HD G Note The above venting diagram shows suggested venting layouts only Consult all appropriate governing bodies or local contractor for venting and fresh air requirements ...

Page 45: ...ct sections Total length needed Qty Length AB XHD HI770 1 x 20 in 25 8 200 ft 200 ft 1 x 20 in 1 25 ft 1 x 16 in 25 6 150 ft 150 ft 2 x 12 in 25 3 75 ft 150 ft HI110 1 x 12 in 25 1 25 ft 25 ft Return ductwork not available HI200 2 x 12 in 25 2 50 ft 100 ft 1 x 14 in 25 1 25 ft 25 ft HI300 1 x 16 in 25 2 50 ft 50 ft HI300 HD 2 x 12 in 25 1 25 ft 50 ft HI400 D G 1 x 20 in 25 4 100 ft 100 ft 1 x 20 i...

Page 46: ...mance connect ducting with flow arrows pointing in the correct direction so the inner seams lie flat during operation Use the screw clamps a at the source to connect the air supply duct adapter to the machine CAUTION Use of Yellow duct rated for 200 F MAX for supply ducting required rating 280 F can result in damage to the duct or unplanned shutdown if the ducting fails Do not use Yellow duct for ...

Page 47: ...r is not available change the adapter arrangement or use one adapter and leave the other adapters open wc_gr013132 wc_gr013134 CAUTION Blocking a duct adapter reduces air flow over the heat exchanger which can cause the high temperature alarm to fault and shut the machine down This can result in damage to the machine or unplanned shutdown Do not block supply air adapters They must remain open or d...

Page 48: ... lock the plug in place Operational notes When the mode switch is set to the upper continuous heat position the heater will operate without a remote thermostat When the mode switch is set to the lower remote thermostat position the heater will not operate unless a remote thermostat is plugged into the receptacle and the signal is read by the controller Thermostat adapter An adapter is available to...

Page 49: ... below to connect power to the machine 1 Verify that the operation mode switch is in the OFF 0 position 2 Connect the main power cord to a properly rated power source Note If the ambient temperature is below freezing wait 10 30 minutes before proceeding WARNING Fire hazard and electric shock hazard The use of under sized extension cords can lead to fire and electric shock Fire and electric shock c...

Page 50: ... gas supply lines if applicable have been properly installed Check that all valves are in the proper operating position Operation mode switch Check that the operation mode switch is in the OFF position Main control panel Check that proper power supplies have been connected at the main control panel See topic Connecting Power to the Machine Remote thermostat if installed Check that the remote therm...

Page 51: ...ne See topic Connecting Power to the Machine 2 Wait 20 30 minutes longer for colder temperatures 3 Start the machine See topic Starting the Machine Note In extreme wind the machine may need to be temporarily blocked from the wind in order to start Troubleshooting 1 If the burner does not start on the first attempt allow the power on sequence to cycle again 2 If after the second power on sequence c...

Page 52: ...l capacity generating maximum heat Operational sequence The following sequence of events will occur 1 The burner blower will start Note An additional heater warms the nozzle to the required operating temperature 2 The burner will start firing In applications in which the remote thermostat is not being used I the burner will fire continuously In applications in which the remote thermostat is being ...

Page 53: ...3 The burner will start firing In applications in which the remote thermostat is not being used I the burner will fire continuously In applications in which the remote thermostat is being used II the burner will fire until the air temperature of the application area reaches the target temperature set by the remote thermostat At that time the burner will shut off but the blower will continue to ope...

Page 54: ... voltage conditions machines equipped with this feature operate as shown in the table below Note The machine can not be reset while the operating status indicator is blinking orange Overriding restart delay To override the 2 minute delay for restarting the machine after the voltage rises above 90 VAC remove the plug from the power receptacle and immediately plug it back in If the problem persists ...

Page 55: ...sition c Shutdown sequence The following sequence of events will occur after turning the machine off 1 The burner will shut down 2 The blower will stop when the machine is sufficiently cool WARNING Electric shock hazard Electric power is still active at the blower even when the machine is turned OFF Remove all electric power to the machine before servicing the machine c ...

Page 56: ...e control panel receptacle c 3 Set the sensor end d within the area to be heated 4 Adjust the target temperature with the dial e Thermostat adapter An adapter is available to convert the proprietary thermostat connection to an Edison plug style connection for use with commonly available thermostats This adapter can be purchased using Wacker Neuson part 5200007098 NOTICE The thermostat adapter is d...

Page 57: ...elow to ensure efficient operation of the machine Refer to the specific topic for details Task When See Topic 1 Install a high elevation kit Item number 5200008502 Before operation 2 Adjust the air damper Before operation 6 7 3 Replace the burner nozzle Before operation 6 6 4 Conduct a combustion analysis and smoke spot test After installing the kit and making any adjustments and or Every 1000 hou...

Page 58: ...nd can be purchased and installed as needed Item Description Purpose Remote thermostat Allows the user to remotely control the target temperature Exhaust pipe An insulated exhaust pipe that offers a method of directing exhaust away from the application area Inlet and outlet covers Vinyl covers that protect the interior of the machine from the elements during transport or storage Duct adapters vari...

Page 59: ...er electric motor and fuel pump Procedure Perform the procedure below to remove the access cover 1 Shut down the machine and allow it to cool 2 Disconnect the power cord from the power source 3 Remove the four screws that fasten the access cover g 4 Remove the access cover and set it aside 5 Perform the required maintenance 6 When maintenance is complete re install the access cover and fasten it w...

Page 60: ...ord from the power source 3 Remove the access cover 4 Remove the screw d to disconnect the ground wire c from the burner assembly b 5 Rotate the burner assembly counterclockwise and remove it from the flame head and air tube assembly e 6 Perform the required maintenance Note Refer to the maintenance procedures in this manual 7 Re install the burner assembly Refer to the steps below to install the ...

Page 61: ... the location of where the last adjustments were made Before starting at a new job site After any burner maintenance or repair has been performed If burner performance is in question Procedure Perform the procedure below to set up the burner 1 Shut down the machine 2 Set the burner electrodes See topic Inspecting Adjusting the Oil Burner Electrodes 3 Check the burner nozzle See topic Checking Chan...

Page 62: ...just before the heater reaches 71 C 160 F 9 Analyze the combustion Follow the combustion analyzer manufacturer s instructions and the general guidelines below Use the access hole in the exhaust stack Take several samples as the heater warms Take the final sample just before the heater reaches 71 C 160 F 10 Re adjust the air band if necessary until the smoke spot test and combustion analysis are wi...

Page 63: ... wrench Procedure 1 Verify that the machine is shut down stopped and connected to electrical power 115V 60 Hz 2 Close the gas valve a on the inlet to the gas train 3 Connect the manometer to the machine 4 Verify that the supply gas pressure is 15 in w c maximum Exceeding the maximum inlet gas pressure may result in gas train component damage 5 Remove the dust cap b on the Maxitrol gas regulator st...

Page 64: ...e 6 Remove the pressure test port plug c located on the bottom of the gas valve 7 Thread the manometer barbed adapter fitting into the test port plug location 8 Connect the manometer d to the barbed adapter fitting This procedure continues on the next page wc_gr015325 c wc_gr015326 wc_gr015327 d ...

Page 65: ...from the previous page 9 Position the gas selector valve for the fuel being used In line for natural gas e 90 for liquid propane LP f 10 Open the gas supply valve g 11 Start the machine h This procedure continues on the next page wc_gr015328 e e f wc_gr015329 g wc_gr015331 h ...

Page 66: ...usting screw clockwise increases the pressure Turning the Maxitrol regulator adjusting screw counterclockwise reduces the pressure 13 Observe a few burner cycles to ensure the gas pressure is set properly 14 After the pressure is set a Shut down the machine b Close the gas supply valve c Remove the manometer and the manometer barbed adapter fitting d Replace the gas valve pressure test plug e Repl...

Page 67: ...rs of operation The condition of the electrodes will drastically affect your machine s ability to fire efficiently Procedure Remove the burner assembly and inspect the condition of the electrode tips a Refer to the table below to determine the condition of the electrode tips The electrodes should be replaced if they are worn or damaged Contact your Wacker Neuson dealer for replacement electrodes C...

Page 68: ...ng the Burner 2 Place an adjustable wrench on the large fitting a on the nozzle base c 3 Place another adjustable wrench on the nozzle b 4 Rotate the nozzle counter clockwise and remove it from the assembly Installing the nozzle 5 Install the new nozzle b onto the nozzle base c 6 Tighten the nozzle b using an adjustable wrench Rotate the wrench clockwise 7 Re install the burner assembly See topic ...

Page 69: ...itudes Check and adjust the air damper when the burner performance is poor Procedure Perform the procedure below to check and adjust the air damper setting 1 The air damper a is located beneath the fan guard 2 To adjust the air damper move the lever left to close O Move the lever right to open 10 Result The air damper has now been adjusted wc_gr011997 Shown with baffle removed for clarity a ...

Page 70: ...e the access cover a 2 Locate the fuel pump b Remove the threaded plug c from the pressure port Set the plug in a safe location to be re installed later This procedure continues on the next page WARNING Electric shock hazard High voltage exists inside the machine High voltage can cause severe injury or death Use extreme care when working inside the machine Disconnect the power source before contin...

Page 71: ... the low fire high fire switch to the high fire position Wait approximately 30 40 seconds to allow the burner to switch from low fire to high fire 9 With the machine running record the value on the gauge This is the high fire reading 10 Set the mode switch to the OFF I position 11 Compare your readings with the recommended pressures Recommended fuel pressures Low fire stage I 181 psi 12 5 bar High...

Page 72: ...the power source 2 Turn the adjusting screws clockwise to increase the pressure counterclockwise to decrease the pressure Turn the adjusting screws in small increments 3 Restart the machine and recheck the fuel pressures Repeat the process until the fuel pressures are adjusted to the recommended pressures 4 Remove the pressure gauge from the pressure test port 5 Re install the threaded plug into t...

Page 73: ...r shell Clean and check adjust burner electrode settings Inspect the heat exchanger Inspect electrical components Inspect the blower motor and belts Replace the belt if necessary Replace the burner nozzle Replace the fuel heater filter Maintain the heater weldment Inspect and test the burner As needed or upon changing job sites see chapter Burner Setup Inspect burner electrodes replace if necessar...

Page 74: ...wing conditions exist The machine has been transported over extremely rough roads or terrain The machine transport vehicle has been involved in an accident The machine has been dropped There is visible damage to the heater shell The burner has been improperly adjusted and is over firing There is doubt about whether regularly scheduled maintenance has been performed The safety systems have been byp...

Page 75: ...mbly c and remove the burner tube assembly from the heat exchanger 4 Remove the bolts that secure the heat exchanger e to the lower shell 5 Lift the heat exchanger out for visual inspection by either of the following methods Use a hoist with non marring straps and approved rigging devices Use a team of four people to lift the heat exchanger by hand using safe lifting practices and techniques The h...

Page 76: ...mbustion chamber while you peer through the burner mounting hole g Look for signs of light inside the combustion chamber Results Do not use the machine if 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 heat exchanger There are cracks or damage to th...

Page 77: ...to the housing a 3 Remove the filter b 4 Inspect the O ring c Replace it if it is cracked damaged or deformed 5 Install the new filter 6 Re install the cover Result The procedure to replace the fuel heater filter is now complete CAUTION Hot surface hazard The external surface of the fuel filter canister may be hot Allow the machine to cool before servicing WARNING Hot fluids The fuel inside the fu...

Page 78: ...wist and pull out the plastic protective holder 1 off the base of the burner assembly The CAD cell 2 is inside this plastic holder 3 Inspect the CAD cell for cleanliness Be sure the cell is free of debris or soot 4 Clean the CAD cell if necessary NOTICE Do NOT use solvents or liquids to clean the CAD cell Use a soft dry cloth to clean the CAD cell 5 Re install the plastic protective holder onto th...

Page 79: ... that secure the fan guard 2 Remove the access panel g See topic Removing the Access Panel 3 Inspect and if necessary clean the motors m using compressed air 4 Clean the fan blades using a stiff brush 5 Re install the internal access panel 6 Re install the fan guard WARNING Electric shock hazard Electric power is still active at the blower even when the machine is turned OFF Remove all electric po...

Page 80: ...ee topic Removing the Access Panel 3 Unscrew and remove the four lift bracket screws a Carefully raise and maneuver the lift bracket b away from the machine shell cover c resting it on the rear frame as shown 4 Remove the six mounting screws and lift the machine shell cover off the machine 5 Inspect and clean the interior shell using compressed air 6 Re install the machine shell cover 7 Re install...

Page 81: ...moving the Access Panel 2 Remove the burner assembly a See topic Removing and Installing the Burner Assembly 3 The flame head is attached to the burner assembly Inspect the flame head for the following Wear Replace if necessary Cleanliness Clean the flame head if necessary Thermal stress Replace if necessary 4 Re install the burner assembly See topic Removing and Installing the Burner Assembly CAU...

Page 82: ...e if necessary Proper ground 7 10 Cleaning the Machine Requirements Machine shut down Machine cool General cleaning Clean the following areas to ensure proper operation 7 11 Item Method task Burner Remove all dirt and debris Ensure that the air intake area is unobstructed Hoses connectors and couplings Wipe clean with cloth Trailer if equipped Clean with compressed air 50 psi maximum Covers machin...

Page 83: ...er nozzle Replace electrodes Check the Cad cell enclosure The burner starts flame ignites but the unit locks out Incorrect fuel pressure Worn burner nozzle Incorrect air lock setting Cad cell defective Burner control defective Increase fuel pressure Replace burner nozzle Re adjust air lock setting The burner ignites but the performance is poor Worn burner nozzle Clogged fuel filter Air leaks in th...

Page 84: ... Fuel nozzle size mm in 3 x 2 8 12 x 0 11 Efficiency 82 7 82 8 Noise level at 1 m dB A 76 74 Power requirement VAC Hz 120 60 120 60 Electrical current 15 C Ampere 13 11 8 Weight no fuel kg lb 206 8 456 225 4 497 Height mm in 1308 51 5 1105 43 5 Length mm in 2134 84 2134 84 Width mm in 838 33 838 33 Flue diameter mm in 152 4 6 152 4 6 Fuel tank capacity L gal 216 1 57 1 Fuel pressure psi bar Stage ...

Page 85: ...wc_td000604gb_FM10 fm 85 HI400HD D HD G Technical Data Notes ...

Page 86: ...11974 12 14 16 6 22 2 11 2 2 13 5 3 6 5 20 18 19 24 17 8 15 9 21 4 10 25 1 L N WH WH WH BK WH YL GN YL GY RD RD RD RD RD RD RD RD RD RD RD BU YL GN WH WH WH WH BU BR BR BU WH WH WH WH WH WH WH WH WH WH WH BK BK BK BK BK BK BK WH WH BR BR GY BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK ...

Page 87: ...citor 18 Preheated nozzle 6 Fan motor 19 Control board heater 7 Electric pilot lamp 20 Starter capacitor 8 Transformer H V 21 Solenoid valve 9 Room thermostat plug 22 Fan thermostat 10 Control box 23 Pressure switch heater 11 Air pressure switch 24 Heater nozzle relay 12 Heated fuel filter 25 Controller fuse 13 Burner motor Wire Colors BK Black RD Red YL Yellow OR Orange GN Green TN Tan BR Brown P...

Page 88: ...975 1 24 16 17 7 11 1 2 2 18 1 13 5 4 6 5 23 19 20 3 8 15 9 21 12 10 22 7 L N WH WH WH BK WH YL GN YL GY RD RD RD RD RD RD RD RD RD BU YL GN YL GN YL GN YL GN YL GN WH WH WH WH WH BU BR WH WH WH WH WH WH WH WH BK BK BK BK BK BK BK BK BK WH WH BK WH BK BK BK BK BK BK BK BK BK BK BK ...

Page 89: ...at 5 Capacitor 18 Flame lamp 6 Fan motor 19 Control board heater 7 Electric pilot lamp 20 Pressure switch heater 8 Transformer H V 21 Gas valve heater 9 Room thermostat plug 22 Controller fuse 10 Control box 23 Starter capacitor 11 Air pressure switch 24 Polarity indicator 12 Ionization probe Wire Colors BK Black RD Red YL Yellow OR Orange GN Green TN Tan BR Brown PU Purple BU Blue VIO Violet CL C...

Page 90: ...975 1 24 16 17 7 11 1 2 2 18 1 13 5 4 6 5 23 19 20 3 8 15 9 21 12 10 22 7 L N WH WH WH BK WH YL GN YL GY RD RD RD RD RD RD RD RD RD BU YL GN YL GN YL GN YL GN YL GN WH WH WH WH WH BU BR WH WH WH WH WH WH WH WH BK BK BK BK BK BK BK BK BK WH WH BK WH BK BK BK BK BK BK BK BK BK BK BK ...

Page 91: ...in 16 Overheat safety thermostat 5 Capacitor 17 Fan thermostat 6 Fan motor 18 Flame lamp 7 Electric pilot lamp 8 Transformer H V 9 Room thermostat plug 10 Control box 22 Controller fuse 11 Air pressure switch 12 Ionization probe 24 Polarity indicator Wire Colors BK Black RD Red YL Yellow OR Orange GN Green TN Tan BR Brown PU Purple BU Blue VIO Violet CL Clear SH Shield PK Pink WH White GY Gray LB ...

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Page 93: ...i zamiennych skontaktuj się z przedstawicielem firmy Wacker Neuson lub skorzystaj z witryny internetowej http wackerneuson com Důležité upozornění Pro informace o náhradních dílech prosím kontaktujte svého Wacker Neuson dealera nebo navštivte webové stránky http www wackerneuson com FONTOS A pótalkatrészekre vonatkozó információkért kérjük forduljon Wacker Neuson kereskedőjéhez vagy látogasson el ...

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