Operator’s Manual
Direct-Fired Air Heater
HDR45 (50 Hz)
Type HDR45 (50 Hz)
Document 5200024456
Date 1115
Version 02
Language EN
5200024456
Copyright notice
© Copyright 2015 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.
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HDR 45 Foreword
Foreword
WARNING
Risk of personal injury or machine damage from improper use.
f Before using the machine, read and understand all instructions and follow them
carefully.
f The manufacturer is not responsible for damages to goods or persons due to
improper 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.
f Before using the machine, read and understand all precautions and instructions
that have been provided. Follow them carefully.
f Only persons who can understand and follow the precautions and instructions
should use or service this machine.
f Contact the manufacturer if you need assistance with operating the machine or
need replacement manuals or labels.
WARNING
Work site fire, burn, inhalation, and explosion hazards.
f Keep solid combustibles, such as building materials, paper, or cardboard at a
safe distance away from the machine.
f Never use this machine in spaces which do or may contain volatile or airborne
combustibles, or products such as gasoline, solvents, paint thinner, dust
particles, or unknown chemicals.
WARNING
Not for use in homes or recreational vehicles. Installing this machine in a home or
RV may result in fire, explosion, property damage, personal injury, or death.
f Operate the machine only as specified in Machine Description and Intended
Use.
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Foreword HDR 45
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
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.
Use the separate Parts Book supplied with the machine to order replacement
parts.
If you are missing any of these documents, please contact Wacker Neuson to
order a replacement or visit 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 observe all instructions
described in this manual.
Machine Item Number
HDR 45 5200013800
wc_gr012365
GRUPPE -
GRUPPE -
TY
TYP
MAX HE
MAX HEA
TING POWER
TING POWER
GASOI
GASOIL
CONSUMPTION
CONSUMPTION
POWER SUPP
POWER SUPPLY
ART
. - NR.
. - NR.
NE
NET
HE
HEA
TING POWER
TING POWER
TOTAL
POWER CONSUMPTION
POWER CONSUMPTION
AIR OUTPU
AIR OUTPUT
VERSION
VERSION
SERIA
SERIAL
NR
NR
W
acker Neuson Corporation
acker Neuson Corporation
Menomonee Falls, WI 53051, US
Menomonee Falls, WI 53051, USA
FUE
FUEL
GROSS WEIGH
GROSS WEIGHT
YEAR
YEAR
Serial Number:
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HDR 45 Foreword
Wacker Neuson expressly reserves the right to make technical modifications,
even without notice, which improve the performance or safety standards of its
machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson reserves the right to change any
portion of this information without notice.
The illustrations, parts, and procedures in this manual refer 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 authorized Wacker
Neuson 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.
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Foreword HDR 45
2015_CE_HDR45_en.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
HDR 45
Heating Equipment
To heat surfaces
5200013800
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, 2004/108/EC
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
L
eo Goeschka, Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München
Menomonee Falls, WI, USA, 09.03.15
Original Declaration of Conformity
Michael Hanson
Engineering Manager
For Wacker Neuson
Keith Herr
Vice President and Managing Director
For Wacker Neuson
Table of Contents
HDR 45
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Foreword 3
EC Declaration of Conformity 7
1 Safety Information 11
1.1 Signal Words Used in this Manual ..................................................... 11
1.2 Machine Description and Intended Use ............................................. 12
1.3 Safety Guidelines for Operating the Machine ..................................... 13
1.4 Safety Guidelines for Operating Combustion Burners ....................... 16
1.5 Service Safety .................................................................................... 17
1.6 Safety Guidelines for Lifting and Transporting the Machine ............... 18
2 Labels 20
2.1 Label Locations .................................................................................. 20
2.2 Label Meanings .................................................................................. 21
3 Lifting and Transporting 24
4 Operation 25
4.1 Preparing the Machine for First Use ................................................... 25
4.2 Parts Included .................................................................................... 26
4.3 Assembling the Machine .................................................................... 27
4.4 Control / Component Locations .......................................................... 28
4.5 Positioning the Machine ..................................................................... 29
4.6 Requirements for the Electric Power Source ..................................... 31
4.7 Connecting to the Power Source ........................................................ 32
4.8 Recommended Fuels and Fuel Blending Guide ................................. 33
4.9 Before Starting Checks ...................................................................... 34
4.10 Starting the Machine in Extremely Cold Weather ............................... 35
4.11 Starting the Machine .......................................................................... 36
4.12 Stopping ............................................................................................. 37
4.13 Operating Status Indicators ................................................................ 37
4.14 Installing and Using the Remote Thermostat ..................................... 38
4.15 Adjusting the Heater Output Angle ..................................................... 39
Table of Contents
HDR 45
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5 Burner Setup 40
5.1 Burner Settings ....................................................................................40
5.2 Removing and Installing the Burner Assembly ....................................41
5.3 Inspecting/Adjusting the Electrodes ....................................................43
5.4 Checking/Changing the Burner Nozzle ...............................................45
5.5 Adjusting the Air Damper ....................................................................46
5.6 Checking and Adjusting the Fuel Pressure .........................................47
6 Maintenance 49
6.1 Periodic Maintenance Schedule ..........................................................49
6.2 Inspecting and Cleaning the Machine .................................................50
6.3 Removing the Access Panels ..............................................................52
6.4 Replacing the Fuel Heater Filter ..........................................................53
6.5 Inspecting, Cleaning, and Testing the Cadmium (CAD) Cell ..............54
6.6 Inspecting the Flame Head .................................................................55
6.7 Inspecting the Electrical Connections .................................................56
6.8 Long Term Storage .............................................................................56
6.9 Machine Disposal / Decommissioning .................................................57
7 Troubleshooting 58
8 Technical Data 60
8.1 Machine ...............................................................................................60
8.2 Dimensions ..........................................................................................61
9 Schematics 62
9.1 Electrical Schematic ............................................................................62
9.2 Components ........................................................................................63
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HDR 45 Safety Information
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.
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 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.
f 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.
f To avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.
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Safety Information HDR 45
1.2 Machine Description and Intended Use
Machine
description
The HDR Heater is a direct-fired radiant heater. The machine operates on diesel
fuel. The machine consists of the following components:
Stainless steel combustion chamber
Blower
Single-stage burner
High-temperature shut-down device
Fuel tank
Safety tip switch
The single-stage burner resides within the dual-walled, cone-shaped combustion
chamber. Fuel is fed to the burner by a fuel pump. Electrodes within the burner
provide spark. Combustion air is provided by the blower. A small amount of blower
air is blown between the walls of the combustion chamber to cool the outermost
wall. As the burner fires, the radiant face becomes hot and radiates clean dry heat.
Combustion gases are vented upwards and away from objects being heated.
Intended use
The HDR Heater is intended to provide heat on outdoor construction sites and in
other rugged applications. Do not use this machine indoors.
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.
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 radiant face 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 offers optional accessories for the machine. These accessories
include the following:
Remote thermostat
Contact your Wacker Neuson dealer for more information.
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HDR 45 Safety Information
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
DANGER
Carbon monoxide. Using the machine indoors CAN KILL YOU IN MINUTES.
Exhaust gas contains carbon monoxide (CO). This is a deadly poison you cannot
see or smell. If you can smell the exhaust, you are breathing CO. Even if you
cannot smell the exhaust, you could be breathing CO.
f NEVER operate the machine inside an enclosed area, such as a home, tunnel,
or garage.
f ONLY use the machine outside and far away from windows, doors, and vents.
These openings can pull in exhaust.
f ALWAYS use a battery-powered or battery-backup CO alarm in nearby struc-
tures. Even when you use the machine correctly, CO may leak into nearby
structures.
f If you start to feel sick, dizzy, or weak after the machine has been running, move
to fresh air IMMEDIATELY. See a doctor. You could have carbon monoxide
poison.
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Safety Information HDR 45
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.
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
Machine
condition
Only operate the machine when:
The combustion chamber 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.
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HDR 45 Safety Information
When operating the machine:
Do not modify or defeat the safety devices.
Do not use worn electrical cords.
Do not use faulty fuel supplies.
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.
f Turn off the machine, wait 10 minutes, disconnect power cord, and let it cool
completely.
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Safety Information HDR 45
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.
Shut down the generator, if equipped, when refueling.
When using the machine:
When refueling the machine:
Do not fill or drain the fuel tank near an open flame 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
Carbon monoxide. Using this machine indoors CAN KILL YOU IN MINUTES.
Exhaust gas contains carbon monoxide (CO). This is a deadly poison you cannot
see or smell. If you can smell the exhaust, you are breathing CO. Even if you
cannot smell the exhaust, you could be breathing CO.
f NEVER operate the machine inside an enclosed area, such as a home, tunnel,
or garage.
f ONLY use the machine outside and far away from windows, doors, and vents.
These openings can pull in exhaust gas.
f ALWAYS use a battery-powered or battery-backup CO alarm in nearby struc-
tures. Even when you use the machine correctly, CO may leak into nearby
structures.
f If you start to feel sick, dizzy, or weak after the machine has been running, move
to fresh air IMMEDIATELY. See a doctor. You could have carbon monoxide
poisoning.
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HDR 45 Safety Information
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.
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Safety Information HDR 45
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 and Transporting 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.
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HDR 45 Safety Information
Notes
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Labels HDR 45
2 Labels
2.1 Label Locations
wc_gr012338
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B
C
D
E
F
G
H
J
A
A
D
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