Wacker Neuson HDR115 User manual

Operator’s Manual
Direct-Fired Air Heater
HDR115
Type HDR115
Document 5100020937
Date 1017
Revision 03
Language EN
5100020937

Copyright notice ©Copyright 2017by 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: [phone] · Fax: [phone] · Tel: [phone]
www.wackerneuson.com
Original instructions This Operator’s Manual presents the original instructions. The original
language of this Operator’s Manual is American English.

HDR 115 Foreword
wc_tx004151gb_FM10.fm 3
Foreword
This heater is designed and approved for use as a construction heater in
accordance with the following standards.
■CSA B140.0-03 3rd Edition (R2008)
■CSA B140.8-1967 (R2001)
■UL 733 4th Edition (Rev. April 22, 2010)
CHECK WITH YOUR LOCAL FIRE SAFETY AUTHORITY IF YOU HAVE
QUESTIONS ABOUT APPLICATIONS.
Other standards govern the use of fuel gases and heat producing products in
specific applications. Your local authority can advise you about these standards.
THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE
REGULATIONS OF THE AUTHORITIES HAVING JURISDICTION.
In addition, as a standard practice for installation, Wacker Neuson recommends
referencing the current issue of CSA B139, Installation Code for Oil Burning
Equipment in Canada and NFPA 31 Standard for the Installation of Oil-Burning
Equipment in the USA.
WARNING
Risk of personal injury or machine damage from improper use.
►Before using the machine, read and understand all instructions and follow them
carefully.
►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.
►Before using the machine, read and understand all precautions and instructions
that have been provided. Follow them carefully.
►Only persons who can understand and follow the precautions and instructions
should use or service this machine.
►Contact the manufacturer if you need assistance with operating the machine or
need replacement manuals or labels.

Foreword HDR 115
4wc_tx004151gb_FM10.fm
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.
WARNING
Work site fire, burn, inhalation, and explosion hazards.
►Keep solid combustibles, such as building materials, paper, or cardboard at a
safe distance away from the machine.
►Never use this machine in spaces which do or may contain volatile or airborne
combustibles, or products such as gasoline, solvents, paint thinner, dust parti-
cles, 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.
►Operate the machine only as specified in the topic Machine Description and
Intended Use.
Machine Item Number
HDR 115 5100018592
5200017248
m3/hrm3/hr
Type/ModelType/Model
gpmgpm
Rev.Rev.
kWkW
lbslbs
kgkg
Item NumberItem Number
Manuf.Yr.Manuf.Yr.
hphp
ftft
m
Serial NumberSerial Number
150188150188
wc_gr013068
Serial Number:

HDR 115 Foreword
wc_tx004151gb_FM10.fm 5
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 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 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.

Foreword HDR 115
6wc_tx004151gb_FM10.fm

Table of Contents
HDR 115
wc_bo5100020937_03TOC.fm 7
Foreword 3
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 Lifting the Machine ........................................... 13
1.5 Safety Guidelines for Operating Combustion Burners ....................... 14
1.6 Service Safety .................................................................................... 15
2 Labels 18
2.1 Label Locations .................................................................................. 18
2.2 Label Meanings .................................................................................. 19
3 Lifting and Transporting 23
3.1 Lifting the Machine ............................................................................. 23
3.2 Transporting the Machine ................................................................... 24
4 Machine Setup 25
4.1 Preparing the Machine for First Use ................................................... 25
4.2 Recommended Fuels ......................................................................... 26
4.3 Refueling the Machine ........................................................................ 27
4.4 Assembling the Machine .................................................................... 28
4.5 Adjusting the Floor Guard .................................................................. 29
4.6 Control / Component Locations .......................................................... 30
4.7 Positioning the Machine ..................................................................... 31
4.8 Adjusting the Heater Output Angle ..................................................... 33
4.9 Electrical and Grounding .................................................................... 34
4.10 Operating Status Indicators ................................................................ 35
5 Operation 36
5.1 Before Starting ................................................................................... 36
5.2 Starting the Machine .......................................................................... 37
5.3 Stopping ............................................................................................. 38
5.4 Emergency Shutdown Procedure ....................................................... 38
5.5 Installing and Using the Remote Thermostat ..................................... 39

Table of Contents HDR 115
wc_bo5100020937_03TOC.fm
8
6 Burner Setup 40
6.1 Removing and Installing the Burner Assembly ....................................40
6.2 Setting up the Burner ..........................................................................41
6.3 Checking and Adjusting the Electrodes ...............................................41
6.4 Inspecting and Replacing the Burner Nozzle ......................................42
6.5 Adjusting the Air Damper ....................................................................43
6.6 Checking and Adjusting the Fuel Pressure .........................................44
7 Maintenance 46
7.1 Periodic Maintenance Schedule ..........................................................46
7.2 Inspecting and Cleaning the Machine .................................................47
7.3 Removing the Access Panel ...............................................................49
7.4 Inspecting and Cleaning the Cadmium (CAD) Cell .............................50
7.5 Inspecting the Electrical Connections .................................................51
7.6 Long Term Storage .............................................................................51
8 Troubleshooting 52
9 Technical Data 54
9.1 Machine ...............................................................................................54
9.2 Dimensions ..........................................................................................54
10 Schematics 55
10.1 HDR 115 ..............................................................................................55

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HDR 115 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.
►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.

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10
Safety Information HDR 115
1.2 Machine Description and Intended Use
This machine is a direct-fired heater. The Wacker Neuson direct-fired heater
operates on diesel fuel, which is consumed in a closed combustion chamber. The
machine consists of a stainless steel combustion chamber, blower, single-stage
burner, high-temperature shut-down device, and a fuel tank. Outside air is pulled
into the machine where it is heated. This clean, dry air is blown between the walls
of the combustion chamber to cool the machine. Access to the blower assembly is
protected by a guard fitted on the air inlet.
This machine 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.
The following are some examples of misuse:
■Connecting to a power source that has voltage and frequency requirements that
are incompatible with the heater requirements
■Operating the heater in a manner that is inconsistent with all federal, state and
local codes and regulations
■Using the machine as a ladder, support, or work surface
■Using the machine to carry or transport passengers or equipment
■Operating the machine outside of factory specifications
■Operating the machine in a manner inconsistent with all warnings found on the
machine and in the Operator’s Manual.
■Not properly securing the heater during transport
■Using the handle to lift the machine
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.
Wacker Neuson offers optional accessories for the machine. These accessories
include the following:
■Remote thermostat

wc_si000963gb_FM10.fm 11
HDR 115 Safety Information
Contact your Wacker Neuson dealer for more 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.
►NEVER operate the machine inside an enclosed area, such as a home, tunnel,
or garage.
►ONLY use the machine outside and far away from windows, doors, and vents.
These openings can pull in exhaust.
►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.
►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.

wc_si000963gb_FM10.fm
12
Safety Information HDR 115
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.
■Do not operate the machine outdoors in storm/rain conditions.
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.
■Ensure stability of the machine on a firm, level surface.
When operating this machine:
■Do not operate a machine in need of repair.
■Do not touch hot surfaces.
WARNING
Fire hazard. Machine positioned on a hill or incline may slide, break away, or roll
over.
►Do not position the machine on a hill or an incline.
►The machine must only be operated when on a firm, level surface.

wc_si000963gb_FM10.fm 13
HDR 115 Safety Information
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
General
operation
safety
Follow the guidelines below when placing the machine in the workspace.
■Position the machine on a firm, noncombustible, level surface.
■Ensure the machine cannot tip over, slide, or fall during operation.
■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.
■Do not operate the machine if it is positioned in pooled water or snow.
■Inspect the machine before startup, and monitor it regularly during operation.
■Do not exceed the maximum heat output of the machine.
■After use, disconnect power from the machine.
After Use ■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, dry location out of the reach of children.
1.4 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 chapter 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.
WARNING
Fire hazard. Do not move the machine while it is operating or 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.

wc_si000963gb_FM10.fm
14
Safety Information HDR 115
1.5 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 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.
►NEVER operate the machine inside an enclosed area, such as a home, tunnel,
or garage.
►ONLY use the machine outside and far away from windows, doors, and vents.
These openings can pull in exhaust gas.
►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.
►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 poi-
soning.

wc_si000963gb_FM10.fm 15
HDR 115 Safety Information
1.6 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 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 operating the machine.
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.
■Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
■Re-install the safety devices and guards after repair and maintenance
procedures are complete.
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.
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.
Replacing
parts and
labels
■Replace worn or damaged components.
■Replace all missing and hard-to-read labels.

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16
Safety Information HDR 115
■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.
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).

wc_si000963gb_FM10.fm 17
HDR 115 Safety Information
Notes

wc_si000964gb_FM10.fm
18
Labels HDR 115
2 Labels
2.1 Label Locations
wc_gr013182
A
A
B
B
C
D
E
E
F
G
H
K
M
N

wc_si000964gb_FM10.fm 19
HDR 115 Labels
2.2 Label Meanings
AWARNING
Hot surface
BNOTICE
Lifting point
CWARNING
Electric shock hazard. Read Operator’s
Manual for instructions.
DCAUTION
This machine uses diesel fuel.
ETie-down point
AVERTISSEMENTAVERTISSEMENT
5100015212
ADVERTENCIAADVERTENCIA
WARNINGWARNING
78 kg
175 LB
5100019484
DIESEL
116679
ATTENTION
ATENCIÓN
CAUTION

wc_si000964gb_FM10.fm
20
Labels HDR 115
FDANGER
Asphyxiation hazard.
Using this machine indoors CAN KILL YOU
IN MINUTES. Burner exhaust and generator
exhaust (if the machine is equipped with a
generator)containscarbonmonoxide. Thisis
a poison you cannot see or smell.
Never use inside an enclosed area even if
doors and windows are open.
Only use outside away from windows, doors,
and vents.
Read the Operator’s Manual before use.
GCAUTION
Hot while in operation. Do not touch. Keep
children, clothing, and combustibles away.
Chaud si en fonction. Ne toucher
pas. Tenir loin les enfants, les
vêtements, et les combustibles.
5200010155
Hot while in operation. Do not
touch. Keep children, clothing,
and combustibles away.
ATENCIÓN
Caliente durante la operación. No
tocar. Manténgase a los niños, ropa
y combustibles alejados.
ATTENTION
CAUTION