2. Wacker Neuson
  3. HI90HD
HI90HD

Wacker Neuson HI90HD, HI35, HI90 User manual

  • Hello! I am an AI chatbot trained to assist you with the Wacker Neuson HI90HD User manual. I’ve already reviewed the document and can help you find the information you need or explain it in simple terms. Just ask your questions, and providing more details will help me assist you more effectively!
Operator’s Manual
Indirect-Fired Air Heaters
HI35
HI60 / HI60HD
HI90 / HI90HD
Type HI35, HI60 / HI60HD, HI90 / HI90HD
Document 5200024469
Date
1017
Version 05
Language
EN
5200024469
Copyright notice
© Copyright 2017 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.
wc_tx003882gb_FM10.fm
3
Foreword
HI35 – HI90
Foreword
SAVE THESE INSTRUCTIONS—This manual contains important instructions for
the machine model below. These instructions have been written expressly by
Wacker Neuson Production Americas LLC and must be followed during installation,
operation, and maintenance of the machine.
This manual covers the machine with the following item number:
Machine
identification
A nameplate listing the model number, item number, revision number, and serial
number is attached to this machine. The location of the nameplate is shown above.
Serial number
(S/N)
For future reference, record the serial number in the space provided below. You will
need the serial number when requesting parts or service for this machine.
Machine Item Number Machine Item Number
HI35 5200019337
HI60 5200019338 HI60HD 5200019339
HI90 5200019340 HI90HD 5200019341
wc_gr012337
Serial Number:
wc_tx003882gb_FM10.fm
4
Foreword
HI35 – HI90
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 parts or requesting service information, be prepared to provide
the machine model number
, item number, revision number, and serial number.
Expectations
for
information in
this manual
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and obser
ve all instructions
describe
d in this manu
al.
Wacker Neuson expressly reserves the right to make technical modifications,
even
without notice, which improve the performance or safety standards of it
s
mac
hines.
The information contained in this manual is based on machines manufactured
up until the time o
f publication. Wacker Neuson reserves the right to cha
nge any
portio
n of this information without notice.
The illustrations, parts, and procedures in this manual refer to Wacker Neuson
facto
ry-installed components. Your machine may vary depending on t
he
require
ments 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 authorized Wacker
Neu
son service center according to written instructions published by Wacker
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 injury hazards to the operator and persons in the work area
Permanent damage to the machine which will not be covered under warranty
Contact your Wacker Neuson dealer immediately if you have questions about
approved or unapproved parts, attachments, or modifications.
2017_CE_HDXX_HIXX_en_FM10.fm
EC Declaration of Conformity
Manufacturer
Wacker Neuson Production Americas LLC, N92W15000 Anthony Avenue,
Menomonee Falls, Wisconsin 53051 USA
Product
Product
Product category
Product function
Item number
HD50, HD70, HI35, HI60, HI60HD, HI90, HI90HD,
HI120, HI120HD
Heating Equipment
To heat air
5200019335, 5200019336, 5200019337, 5200019338,
5200019339, 5200019340, 5200019341, 5200019342,
5200019343
Directives and Standards
We hereby declare that this product meets and complies with the relevant regulations and
requirements of the following directives and standards:
2006/42/EC, 2006/95/EC, 2014/30/EU
EN 13842: 2004
EN 60335-1:2002 + A1:2004 + A11:2004 + A2:2006 + A12:2006 + A13:2008 + A14:2010
EN 60335-2-102:2006 + A1:2010
EN 60529:1991 + EN 60529 corr:1993 + A1:2000
EN 55014-1:2008
EN 61000-3-2:2007
EN 61000-3-3:1997 + A1:2002 + A2/IS\1:2006
Authorized Person for Technical Documents
Robert Raethsel, Wacker Neuson Produktion GmbH & Co. KG, Wackerstrasse 6,
85084 Reichertshofen, Germany
Menomonee Falls, WI, USA, 07.04.17
Original Declaration of Conformity
Keith Herr
Vice President and Managing Director
For Wacker Neuson
Michael Hanson
Manager, Product Engineering
For Wacker Neuson
Jeff Volden
Director, Product Engineering
For Wacker Neuson
Table of Contents
HI35 – HI90
wc_bo5200024469_05TOC
7
Foreword 3
EC Declaration of Conformity 5
1 Safety Information 9
1.1 Signal Words Used in this Manual ....................................................... 9
1.2 Machine Description and Intended Use ............................................. 10
1.3 Safety Guidelines for Operating the Machine ..................................... 11
1.4 Safety Guidelines for Operating Combustion Burners ....................... 13
1.5 Service Safety .................................................................................... 14
1.6 Safety Guidelines for Lifting the Machine ........................................... 15
2 Labels 16
2.1 Label Locations .................................................................................. 16
2.2 Label Meanings .................................................................................. 17
3 Lifting and Transporting 20
3.1 Lifting the Machine ............................................................................. 20
3.2 Transporting the Machine ................................................................... 22
4 Operation 23
4.1 Preparing the Machine for First Use ................................................... 23
4.2 Assembling the Machine .................................................................... 24
4.3 Installing the Front Duct Adapter ........................................................ 25
4.4 Flex Ducting Options .......................................................................... 26
4.5 Ducting Guidelines ............................................................................. 27
4.6 Control and Component Locations ..................................................... 29
4.7 Machine Components Descriptions .................................................... 29
4.8 Positioning the Machine ..................................................................... 30
4.9 Requirements for the Electric Power Source ..................................... 31
4.10 Connecting to the Power Source ........................................................ 32
4.11 Recommended Fuels and Fuel Blending Guide ................................. 33
4.12 Venting the Machine ........................................................................... 34
4.13 Operating Status Indicators ................................................................ 36
4.14 Control Panel ...................................................................................... 37
4.15 Before Starting Checks ...................................................................... 38
4.16 Inspecting the Fuel Hose .................................................................... 38
Table of Contents
HI35 – HI90
8
4.17 Starting the Machine ...........................................................................39
4.18 Starting the Machine in Extremely Cold Weather ................................40
4.19 Stopping ..............................................................................................40
4.20 Installing and Using the Remote Thermostat ......................................41
4.21 Using the Fuel Valve (Bleeding the Fuel System) ...............................42
5 Burner Setup 43
5.1 Factory Settings ..................................................................................43
5.2 Removing the Access Cover ...............................................................43
5.3 Burner Setup .......................................................................................44
5.4 Inspecting and Adjusting the Oil Burner Electrodes ............................46
5.5 Checking and Changing the Burner Nozzle ........................................48
5.6 Checking and Adjusting the Fuel Pressure .........................................49
5.7 Setting the Air Band ............................................................................51
6 Maintenance 52
6.1 Periodic Maintenance Schedule ..........................................................52
6.2 Inspecting the Heat Exchanger ...........................................................53
6.3 Inspecting and Changing the Fuel Heater Filter ..................................56
6.4 Inspecting, Cleaning, and Testing the Cadmium (CAD) Cell ..............57
6.5 Inspecting the Flame Head .................................................................58
6.6 Cleaning and Replacing the Fuel Filter ...............................................59
6.7 Inspecting the Electrical Connections .................................................60
6.8 Long Term Storage .............................................................................60
6.9 Machine Disposal and Decommissioning ............................................61
7 Troubleshooting 62
8 Technical Data 63
8.1 Machine ...............................................................................................63
8.2 Dimensions ..........................................................................................64
9 Schematics 65
9.1 Electrical Schematic—HI35, HI60, HI90 ..............................................65
9.2 Components—HI35, HI60, HI90 ..........................................................66
9.3 Electrical Schematic—HI60HD, HI90HD .............................................67
9.4 Components—HI60HD, HI90HD .........................................................68
HI35 – HI90 Safety Information
wc_si000909gb_FM10.fm 9
1 Safety Information
1.1 Signal Words Used in this Manual
This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE
signal words which must be followed to reduce the possibility of personal injury,
damage to the equipment, or improper service.
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
Obey all safety messages that follow this symbol.
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 injury.
To avoid possible death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
To avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.
Safety Information HI35 – HI90
10 wc_si000909gb_FM10.fm
1.2 Machine Description and Intended Use
Machine
description
The HI Heater is an indirect-fired air heater that operates on diesel fuel. The
machine consists of the following components:
Stainless steel combustion chamber and heat exchanger
Blower
Single-stage burner
High-temperature shut-down device
Fuel tank
Fuel is consumed in a closed combustion chamber. Room air or outside air
(depending on the application) is pulled into the machine where it is heated. This
clean, dry, hot air is then blown into the space to be heated by the blower. Access
to the blower assembly is protected by a guard fitted on the air inlet.
Intended use
The HI Heater is intended to provide heat on outdoor or indoor construction sites (if
properly vented) and in other rugged applications.
This machine has been designed and built strictly for the intended use described
above. Using the machine for any other 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 has been carefully engineered to eliminate hazards as far as
practicable and to increase operator safety through protective guards and labeling.
However, some risks may remain even after protective measures have been taken.
They are called residual risks. On this machine, they may include exposure to:
exhaust emissions
hot surfaces such as exhaust vents and fuel heater
fuel and fuel fumes when refueling
high voltages and arc flash
To protect yourself and others, make sure you thoroughly read and understand the
safety information presented in this manual before operating the machine.
Optional
accessories
Wacker Neuson Corporation offers many optional accessories for the machine.
These accessories include the following:
Remote thermostat
Contact your Wacker Neuson dealer for more information.
HI35 – HI90 Safety Information
wc_si000909gb_FM10.fm 11
1.3 Safety Guidelines for Operating the Machine
Operator
training
Before operating the machine:
Read and understand the operating instructions contained in all manuals
delivered with the machine.
Familiarize yourself with the location and proper use of all controls and safety
devices.
Contact Wacker Neuson for additional training if necessary.
When operating this machine:
Do not allow improperly trained people to operate the machine. People
operating the machine must be familiar with the potential risks and hazards
associated with it.
Operator
qualifications
Only trained personnel are permitted to start, operate, and shut down the machine.
They also must meet the following qualifications:
have received instruction on how to properly use the machine
are familiar with required safety 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 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.
Be aware of the application area.
Do not operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
Safety
devices,
controls, and
attachments
Only operate the machine when:
All safety devices and guards are in place and in working order.
All controls operate correctly.
The machine is set up correctly according to the instructions in the Operator’s
Manual.
The machine is clean.
The machine’s labels are legible.
To ensure safe operation of the machine:
Do not operate the machine if any safety devices or guards are missing or
inoperative.
Do not modify or defeat the safety devices.
Only use accessories or attachments that are approved by Wacker Neuson.
Safety Information HI35 – HI90
12 wc_si000909gb_FM10.fm
Safe
operating
practices
When operating this machine:
Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
When operating this machine:
Do not operate a machine in need of repair.
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while operating this
machine:
Close-fitting work clothes that do not hinder movement
Safety glasses with side shields
Hearing protection
Safety-toed footwear
Work space
Follow the guidelines below when placing the machine in the workspace.
Position 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 machine clear of debris that could fall on the machine.
Do not position electrical cords under the machine or over the top of the
machine.
After Use
1. Turn the machine off and allow it to cool.
2. Disconnect power from the machine.
3. Ensure that the machine will not tip over, roll, slide, or fall when not being
operated.
4. Store the machine properly when it is not being used. The machine should be
stored in a clean, dry location out of the reach of children.
WARNING
Fire hazard. Do not move the machine while it is plugged in, even if power is lost.
Turn off the machine, wait 10 minutes, disconnect power cord, and let it cool
completely.
HI35 – HI90 Safety Information
wc_si000909gb_FM10.fm 13
1.4 Safety Guidelines for Operating Combustion Burners
When using the machine:
Clean up any spilled fuel immediately.
Replace the fuel tank cap after refueling the machine.
Refill the fuel tank in a well-ventilated area.
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 not use gasoline, crankcase oil, or any oil containing gasoline.
DANGER
Exhaust gas from the burner contains carbon monoxide, a deadly poison. Exposure
to carbon monoxide can kill you in minutes.
Never run the machine indoors or in an enclosed area unless the machine is
vented properly according to local and national codes.
Safety Information HI35 – HI90
14 wc_si000909gb_FM10.fm
1.5 Service Safety
Service
training
Before servicing or maintaining the machine:
Read and understand the instructions contained in all manuals delivered with
the machine.
Familiarize yourself with the location and proper use of all controls and safety
devices.
Only trained personnel shall troubleshoot or repair problems occurring with the
machine.
Contact Wacker Neuson for additional training if necessary.
When servicing or maintaining this machine:
Do not allow improperly trained people to service or maintain the machine.
Personnel servicing or maintaining the machine must be familiar with the
associated potential risks and hazards.
Precautions
Follow the precautions below when servicing or maintaining the machine.
Read and understand the service procedures before performing any service to
the machine.
All adjustments and repairs must be completed before operation. Do not
operate the machine with a known problem or deficiency.
All repairs 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.
When servicing or maintaining the machine:
Do not defeat safety devices.
Do not modify the machine without the express written approval of Wacker
Neuson.
Replacing
parts and
labels
Replace worn or damaged components.
Replace all missing and hard-to-read labels.
When replacing electrical components, use components that are identical in
rating and performance to the original components.
When replacement parts are required for this machine, use only Wacker
Neuson replacement parts or those parts equivalent to the original in all types of
specifications, such as physical dimensions, type, strength, and material.
Cleaning
When cleaning and servicing the machine:
Keep the machine clean and free of debris such as leaves, paper, cartons, etc.
Keep the labels legible.
When cleaning the machine:
Do not clean the machine while it is running.
Never use gasoline or other types of fuels or flammable solvents to clean the
machine. Fumes from fuels and solvents can become explosive.
HI35 – HI90 Safety Information
wc_si000909gb_FM10.fm 15
Personal
Protective
Equipment
(PPE)
Wear the following Personal Protective Equipment (PPE) while servicing or
maintaining this machine:
Close-fitting work clothes that do not hinder movement
Safety glasses with side shields
Hearing protection
Safety-toed footwear
In addition, before servicing or maintaining the machine:
Tie back long hair.
Remove all jewelry (including rings).
1.6 Safety Guidelines for Lifting the Machine
When lifting the machine:
Make sure slings, chains, hooks, ramps, jacks, forklifts, cranes, hoists, and any
other type of lifting device used is attached securely and has enough weight-
bearing capacity to lift 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 the Operator’s Manual.
Make sure the transporting vehicle has sufficient load capacity and platform size
to safely transport the machine.
To reduce the possibility of injury:
Do not stand under the machine while it is being lifted or moved.
Do not get onto the machine while it is being lifted or moved.
wc_si000914gb_FM10.fm
16
Labels HI35 – HI90
2 Labels
2.1 Label Locations
wc_gr012461
HI 35
A
B
C
D
E
F
G
H
H
G
wc_gr012462
A
B
C
D
E
F
G
H
J
G
H
A
HI 60 / HI 60HD / HI 90 / HI 90HD
wc_si000914gb_FM10.fm
17
HI35 – HI90 Labels
2.2 Label Meanings
1
A WARNING
Hot surface
B WARNING
Electric shock hazard.
Disconnect power before servicing.
Read Operator’s Manual.
C CAUTION
This machine uses diesel fuel.
D DANGER
Asphyxiation hazard. Heater exhaust contains
carbon monoxide. This is a poison you cannot
see or smell.
Do not operate this machine indoors or in an
enclosed area unless the machine is vented
properly according to local and national codes.
Read the Operator’s Manual.
5200020709
181146
181145181145
52000221745200022174
wc_si000914gb_FM10.fm
18
Labels HI35 – HI90
E WARNING
Read and understand the supplied Operator's
Manual before operating this machine.
The requirements of local authorities having
jurisdiction shall be followed.
Do not use heater in close proximity of
combustible surfaces or materials.
Ensure fresh air supply to space where heater
is used.
Equipment must be grounded.
Use only diesel fuel No. 2 or kerosene.
Do not use gasoline or crankcase drain oil.
Do not fill the tank while the unit is operating.
Never pull electrical socket while heater is
running.
Do not start the heater when the combustion
chamber is hot.
Do not start the heater when excess oil has
accumulated in the chamber.
Allow unit to cool before shutdown. Stop heater
only at control panel switch in order to ensure
automatic cooling off. Heater will stop by itself
after automatic cooling off.
Clean fuel filter regularly and drain water from
fuel tank if necessary.
When heater is first used after a long storage
period it might be necessary to reset the
machine up to three times by the reset button.
The button will light up; wait two minutes before
resetting.
Do not tamper with the unit. Have a competent
service technician make any adjustments.
Unplug machine before removing the cover for
any maintenance.
Machine must only be operated in a firm, level
surface.
Never operate when heater or extension cord
are resting in pooled water or snow.
wc_si000914gb_FM10.fm
19
HI35 – HI90 Labels
F WARNING
Cutting hazard. Keep hands and feet away from
moving blade.
G NOTICE
Lifting point
H Tie-down point.
J Read the Operator’s Manual.
Setting the valve to this position (down) directs
the fuel back to the tank.
Setting the valve to this position (up) directs the
fuel to the burner.
5200021884
5200021884
Lifting and Transporting HI35 – HI90
20 wc_tx003883gb_FM10.fm
3 Lifting and Transporting
3.1 Lifting the Machine
Requirements
Lifting equipment (crane, hoist, or fork lift truck) capable of supporting the
machine’s weight. See Chapter Technical Data.
Lifting devices (hooks, chains, and shackles) capable of supporting the
machine’s weight
Machine stopped
All venting removed from the heater (if equipped)
NOTICES Do not tow this machine.
Do not route tie-down straps or chains over the top of the machine.
Fuel may leak from the fuel tank cap during lifting. Before lifting, remove fuel
from the machine, if necessary. Clean up any leaked fuel before using the
machine.
Procedure
Perform the procedure below to lift the machine.
1. Turn off the machine and let the machine cool completely.
2. Disconnect the power cord.
3. Cover all openings on the machine to avoid infiltration from road debris and
dust.
This procedure continues on the next page.
WARNING
Crushing hazard.
Only qualified riggers should attempt aerial lifting of this machine.
WARNING
Crushing hazard. You may be crushed if the lifting devices fail.
Never stand under, or get onto, the machine while it is being lifted or moved.
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
/