Wacker Neuson HI 400 HD D User manual

0192824 001 1110
0192824
Operator’s Manual
Indirect-Fired Air Heaters
HI 400 HD D
HI 400 HD G

Copyright
notice
© Copyright 2010 by Wacker Neuson Corporation.
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 Corporation.
Any type of reproduction or distribution not authorized by Wacker Neuson Corporation
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 Corporation
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.

Foreword
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Foreword
This heater is designed and approved for use as a construction heater in
accordance with Standard ANSI Z83.7–CSGA 2.14. 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.
THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE
REGULATIONS OF THE AUTHORITIES HAVING JURISDICTION.
WARNING
Risk of personal injury or machine damage from improper use.
fBefore using the machine, read and understand all instructions and follow them
carefully.
fThe 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.
fBefore using the machine, read and understand all precautions and instructions
that have been provided. Follow them carefully.
fOnly persons who can understand and follow the precautions and instructions
should use or service this machine.
fContact 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.
fKeep solid combustibles, such as building materials, paper, or cardboard at a
safe distance away from the machine as recommended by the instructions.
fNever 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.
fOperate the machine only for applications specified in Machine Description and
Intended Use.

Foreword
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Machines
covered by
this manual
This manual covers machines with the following item numbers:
Machine
documentation
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
Corporation 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.
Wacker Neuson Corporation 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 Corporation reserves the right
to change any portion of this information without notice.
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 ser-
vice 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.
Machine Item Number
HI 400HD D 0620868
HI 400HD G 0620701

HI 400HD D / HD G Table of Contents
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Foreword 3
1 Safety Information 7
1.1 Signal Words Used in this Manual ....................................................... 7
1.2 Machine Description and Intended Use ............................................... 8
1.3 Operating Safety .................................................................................. 9
1.4 Safety Guidelines for Gas-Fired Machines ......................................... 10
1.5 Safety Guidelines for Operating Combustion Burners ....................... 11
1.6 Service Safety .................................................................................... 12
2 Labels 14
2.1 Label Locations .................................................................................. 14
2.2 Label Meanings .................................................................................. 15
3 Lifting and Transporting 18
3.1 Lifting and Transporting ...................................................................... 18
4 Operation 19
4.1 Preparing the Machine for First Use ................................................... 19
4.2 Installing the Axle and Wheels ........................................................... 19
4.3 Installing the Front Duct Adapter ........................................................ 20
4.4 Installing the Rear Duct Adapter (optional) ........................................ 21
4.5 Control / Component Locations .......................................................... 22
4.6 Adjusting the Handle Height ............................................................... 23
4.7 Positioning the Machine ..................................................................... 24
4.8 Control Panel—Oil Burner (D Models) ............................................... 26
4.9 Recommended Fuels and Fuel Blending Guide (D models) .............. 27
4.10 Inspecting the Fuel Hose .................................................................... 27
4.11 Control Panel—Gas Burner (G Models) ............................................. 28
4.12 Gas Installation and Setup (G models) .............................................. 29
4.13 Connecting the Gas Line (G models) ................................................. 30
4.14 Setting the Gas Selector Valve (G models) ........................................ 31
4.15 Suggested Venting ............................................................................. 32
4.16 Installing the Heater Duct ................................................................... 34
4.17 Installing the Remote Thermostat or Receptacle Cap ........................ 35
4.18 Connecting Power to the Machine (Preheating) ................................. 36
4.19 Starting the Machine in Extremely Cold Weather ............................... 37
4.20 Before Starting ................................................................................... 38

Table of Contents HI 400HD D / HD G
6 wc_bo0182003en_001TOC.fm
4.21 Starting the Machine (D models) .........................................................39
4.22 Starting the Machine (G models) .........................................................40
4.23 Stopping ..............................................................................................41
4.24 Burner Fault .........................................................................................41
4.25 Installing and Using the Remote Thermostat ......................................42
5 Accessories 43
5.1 Available Accessories .........................................................................43
6 Burner Setup 44
6.1 Removing the Access Panel ...............................................................44
6.2 Removing and Installing the Burner ....................................................45
6.3 Inspecting the Oil Burner Electrodes (D models) ................................48
6.4 Checking/Changing the Burner Nozzle (D models) .............................49
6.5 Adjusting the Burner Air Damper Setting ............................................50
6.6 Adjusting the Fuel Pressure (D models) ..............................................51
7 Maintenance 53
7.1 Periodic Maintenance Schedule ..........................................................53
7.2 Changing the Fuel Heater Filter (D models) ........................................54
7.3 Inspecting and Cleaning the Cadmium (CAD) Cell .............................55
7.4 Cleaning the Fan Blades and Motor ....................................................56
7.5 Cleaning the Interior Shell ...................................................................57
7.6 Inspecting the Flame Head .................................................................58
7.7 Inspecting the Electrical Connections .................................................59
7.8 General Cleaning Guidelines ..............................................................59
8 Technical Data 62
8.1 Machine ...............................................................................................62
9 Schematics 63
9.1 HI 400HD D—Oil Burning ....................................................................63
9.2 Components—Oil Burning ...................................................................64
9.3 HI 400HD G—Gas Burning .................................................................65
9.4 Components—Gas Burning ................................................................66

HI 400HD D / HD G Safety Information
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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.
fObey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
fTo 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.
fTo avoid possible death or serious injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
CAUTION!
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
fTo avoid possible minor or moderate injury from this type of hazard, obey all safety mes-
sages that follow this signal word.

Safety Information HI 400HD D / HD G
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1.2 Machine Description and Intended Use
Machine
description
The HI Heater is an indirect-fired air heater. Depending on the model, the machine
operates either on diesel fuel (oil) or natural gas / liquid propane (LP). The machine
consists of the following components:
Stainless steel combustion chamber and heat exchanger
Blower
Two-stage burner (oil model)
High-temperature shut-down device
Fuel tank (oil model)
Gas selector valve (gas model)
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
Duct adapters (various sizes, available as kits, or individual ducts at 25 ft.
lengths).
Exhaust vents and elbows
Contact your Wacker Neuson dealer for more information.

HI 400HD D / HD G Safety Information
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1.3 Operating Safety
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 Corporation 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.
Machine
condition
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.
When operating the machine:
Do not modify or defeat the safety devices.
Do not use worn electrical cords.
Do not use faulty fuel supplies.
Guidelines for
operator
When operating the machine:
Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
Wear protective clothing appropriate to the job site when operating the machine.
Wear safety glasses.
When operating the machine:
Do not operate a machine in need of repair.
Do not smoke near the machine.
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.

Safety Information HI 400HD D / HD G
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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.
Keep unauthorized personnel, children, and animals away from the machine.
Do not connect ductwork between the exhaust outlet port and thesupply air inlet
port.
Do not position the electrical cords under the machine or over the top of the
machine.
While
operating the
machine
Inspect the machine before startup, and monitor it regularly during operation.
Never exceed the maximum heat output of the machine.
Never operate the machine in areas that contain flammable objects, fuels, or
products that produce flammable vapors.
After use Disconnnect power from the machine.
Store the machine properly when it is not being used.
1.4 Safety Guidelines for Gas-Fired Machines
Proper gas supply must be provided to the inlet of the machine. Refer to the rating
plate for the correct gas supply pressure.
Gas pressure above the maximum specified on the rating plate can cause fire or
explosions, leading to serious injury, death, or property loss.
Gas pressure below the minimum specified on the rating plate may cause
improper combustion, leading to asphyxiation or carbon monoxide poisoning.
Before operating the machine, read and follow 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.
WARNING
Gas leaks can cause explosions or fire. Follow the steps below if you smell gas.
fOpen windows.
fDo not touch electrical switches.
fExtinguish open flames.
fImmediately call your gas supplier.
WARNING
Risk of explosion, fire, property damage, asphyxiation, death, or carbon monoxide
poisoning.
fRead and follow the instructions below regarding proper gas supply and prepa-
ration of the machine.

HI 400HD D / HD G Safety Information
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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.
Make sure you have proper certification or licensing required by the locality,
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 monox-
ide, a deadly poison. Exposure to carbon monoxide can kill you in minutes.
fNever run the machine indoors or in an enclosed area unless the machine is
vented properly according to local and national codes.

Safety Information HI 400HD D / HD G
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1.6 Service Safety
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).
Licensing/
training/
Only qualified personnel who possess the proper certification or license
required by the locality, state, or province in which the machine is being installed
are allowed to make connections to natural gas or LP.
Only trained personnel should troubleshoot or repair electrical problems
occurring with the machine.
Cleaning When cleaning and servicing the machine:
Keep the area around the burner free of debris such as leaves, paper, cartons,
etc.
Keep the machine clean and 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 parts.
Fumes from fuels and solvents can become explosive.
Maintenance
guidelines
When maintaining the machine:
Keep the fuel lines in good condition and properly connected.
Allow the burner to cool before maintaining the machine.
Re-install the safety devices and guards after repairs and maintenance.
Keep all electrical cords away from heat, oil, vibrating surfaces, and sharp
edges.
Inspect all electrical cords before each use and replace damaged cords.
Replacing
parts and
labels
When maintaining the machine:
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.
Replace worn or damaged components.
Replace all missing and hard-to-read labels.
Replace or repair electrical components with components that are identical in
rating and performance as the original component.

HI 400HD D / HD G Safety Information
ghi_si000468gb.fm 13
Accessories,
safetydevices
and
modifications
When using the machine:
Use only accessories/attachments that are recommended by
Wacker Neuson Corporation.
When using the machine:
Never operate the machine if any safety devices or guards are missing or
inoperative.
Do not defeat safety devices.
Do not modify the machine without the express written approval of the
manufacturer.

Labels HI 400HD D / HD G
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2 Labels
2.1 Label Locations
ghi_gr007391
AC
H
F
(4)
O
J
B
E
RP
K
M
DGQ
K

HI 400HD D / HD G Labels
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2.2 Label Meanings
AWARNING!
Hot surface!
B WARNING
Entanglement hazard. Rotating machinery.
Do not reach inside machine when engine is
running.
C NOTICE
Lifting point.
D WARNING!
Electric shock hazard.
Disconnect power before servicing.
Read Operator’s Manual.
ECAUTION
This machine uses diesel fuel.
F Tie-down point.

Labels HI 400HD D / HD G
16 ghi_si000469gb.fm
GDANGER
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.
HCAUTION
Hot while in operation. Do not touch. Keep
children, clothing, and combustibles away.
J Safety instruction label for diesel fuelled
heaters
K A nameplate listing the model number, item
number, revision number, and serial number
is attached to each unit. Please record the
information found on this plate so it will be
available should the nameplate become lost
or damaged. When ordering parts or
requesting service information, you will
always be asked to specify the model num-
ber, item number, revision number, and serial
number of the unit.
May not be on your machine.
L Gas selector valve
Propane Gas Position
Natural Gas Position
Lock valve in position after selection.
M Heater rating plate

HI 400HD D / HD G Labels
ghi_si000469gb.fm 17
N WARNING
Licensed gas technician required.
Natural gas / liquidpropane burner setup and
installation, fuel supply connection, test
firing, and burner adjustment MUST be
performed by a LICENSED professional gas
technician and must conform to the
requirements of all relevant local, state,
provincial, and Federal authorities.
Failure to heed this warning may result in an
explosion and/or fire causing property
damage, personal injury, or death.
O General usage warnings
P Hose assembly specification
Q Electrical grounding instructions
R Gas type label

Lifting and Transporting HI 400HD D / HD G
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3 Lifting and Transporting
3.1 Lifting and Transporting
Requirements Transport vehicle capable of carrying 1000 lbs (454 kg)
Crane or lift capable of carrying 1000 lbs (454 kg)
Background NOTICE: These machines are NOT designed to be towed with any vehicle.
Guidelines Follow the guidelines below when lifting and transporting this machine.
 Remove all venting from the machine prior to lifting/transporting.
 Cover all openings 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 frame only.
NOTICE: Do not route tie-down straps or chains over the top of the machine.
Doing so will damage the machine. Use only the designated tie-down locations.
WARNING
Crushing hazard.
fOnly qualified riggers should attempt aerial lifting of this machine.

HI 400HD D / HD G Operation
ghi_tx001462gb.fm 19
4 Operation
4.1 Preparing the Machine for First Use
Preparing for
first use
To prepare your machine for first use:
1. Make sure all loose packaging materials have been removed from the machine.
2. Check the machine and its components for damage. If there is visible damage,
do not operate the machine! Contact your Wacker Neuson dealer immediately
for assistance.
3. Take inventory of all items included with the machine and verify that all loose
components and fasteners are accounted for.
4. Attach component parts not already attached.
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 Follow the procedure below to install the axle and wheels.
1. Lift the machine using appropriate lifting gear.
2. Slide the axle (a) into the tube (b) beneath the trailer.
3. Place a wheel (c) and flat washer (d) on each end of the axle as shown.
4. Insert hitch pins (e) into the holes at each end of the axle to secure the wheels.
WARNING
Crushing hazard.
fRefer to chapter Lifting the Machine for instructions on proper lifting techniques.
wc_gr007904
a b
e
d
c

Operation HI 400HD D / HD G
20 ghi_tx001462gb.fm
4.3 Installing the Front Duct Adapter
Overview The front duct adapter provided with your machine is shipped loose and must be
installed before operating the machine. The thermostat probe must also be
installed on the inside of the duct adapter during this procedure.
Procedure Follow the procedure 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 inside the
machine shell.
Note: Do not discard the screw. It will be used to mount the thermostat probe.
3. Slide the edge of the duct adapter (d) beneath the edges of the upper and lower
machine shell.
4. Align the four threaded mounting holes (e) on the duct adapter with the
corresponding holes on the machine shell.
5. Use the screws (provided) to fasten the duct adapter to the machine shell.
6. Align the thermostat probe inside the duct adapter as shown. Fasten the
thermostat probe in place using the reserved bracket screw.
wc_gr007766
a
a
b
c
d
e