Wacker Neuson Arctic Bear XHD Manuel utilisateur

5200004570 04 0212

Operator’s Manual

IDF Heater

HI 770XHD

Notice d’Emploi

Réchauffeurs d’air–Mise à feu indirecte

5200004570

Copyright

notice

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.

5200003388 02 1211

HI 770XHD Foreword

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Foreword

SAVE THESE INSTRUCTIONS—This manual contains important instructions for

the machine models below. These instructions have been written expressly by

Wacker Neuson Production Americas LLC and must be followed during installation,

operation, and maintenance of the machines.

Machines

covered by

this manual

This manual covers machines with the following item numbers:

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 either 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.

 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.

CALIFORNIA

Proposition

65 Warning

Engine exhaust, some of its constituents, and certain vehicle components, contain

or emit chemicals known to the State of California to cause cancer and birth

defects or other reproductive harm.

Laws

pertaining to

spark

arresters

NOTICE: State Health Safety Codes and Public Resources Codes specify that in

certain locations spark arresters be used on internal combustion engines that use

hydrocarbon fuels. A spark arrester is a device designed to prevent accidental

discharge of sparks or flames from the engine exhaust. Spark arresters are

qualified and rated by the United States Forest Service for this purpose. In order to

comply with local laws regarding spark arresters, consult the engine distributor or

the local Health and Safety Administrator.

Manufacturer’s

approval

This manual contains references to approved parts, attachments, and

modifications. The following definitions apply:

Machine Item Number

HI 770XHD 5000620183, 5000620676,

5200003814, 5200004934

Foreword HI 770XHD

4 wc_tx001880gb.fm

 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.

Table of Contents

HI 770XHD

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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 Operating Combustion Burners ....................... 13

1.5 Service Safety .................................................................................... 14

1.6 Safety Guidelines for Operating Gensets ........................................... 16

1.7 Safety Guidelines for Towing the Machine ......................................... 18

1.8 Safety Guidelines for Lifting the Machine ........................................... 19

2 Labels 20

2.1 Label Locations ................................................................................ 20

2.2 Label Meanings .................................................................................. 21

3 Lifting and Transporting 28

3.1 Lifting the Machine ............................................................................. 28

3.2 Preparing the Machine for Transport on a Truck or Trailer ................ 29

3.3 Transporting the Machine on a Truck or Trailer ................................. 30

3.4 Before Towing Checklist ..................................................................... 31

3.5 Towing the Machine ........................................................................... 32

3.6 Testing the Breakaway System (Electric Brakes) .............................. 33

4 Operation 35

4.1 External Components ......................................................................... 35

4.2 Burner Compartment Components .................................................... 36

4.3 Generator Compartment Components ............................................... 37

4.4 120VAC / 208VAC Control Panel ....................................................... 38

4.5 DC Control Panel ............................................................................... 39

4.6 Temperature Controller ...................................................................... 40

4.7 Connecting and Accessing 120VAC Shore Power ............................. 41

4.8 General Sequence of Operation ......................................................... 42

4.9 Positioning the Machine ..................................................................... 43

4.10 Grounding the Machine ...................................................................... 45

4.11 Pre-Starting Checks ........................................................................... 46

4.12 Recommended Fuel ........................................................................... 47

4.13 Refueling the Machine ........................................................................ 48

Table of Contents

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4.14 Installing the Heater Duct ....................................................................49

4.15 Starting the Generator Engine .............................................................50

4.16 Starting and Running the Machine ......................................................51

4.17 Using the Recircul-Air Feature ............................................................53

4.18 Stopping the Machine ..........................................................................54

4.19 Emergency Stop Procedure ................................................................56

5 Accessories 57

5.1 Available Accessories .........................................................................57

5.2 Removing and Installing a Duct Adapter .............................................58

5.3 Flex Ducting Options ...........................................................................59

6 Burner Setup 60

6.1 Factory Settings ..................................................................................60

6.2 Setting up the Burner ..........................................................................60

6.3 Recommended Fuel ............................................................................61

6.4 Burner Components ............................................................................62

6.5 Removing and Installing the Combustion Head Assembly ..................63

6.6 Recommended Burner Nozzles ..........................................................65

6.7 Replacing the Burner Nozzle ...............................................................66

6.8 Checking and Adjusting the Electrode Position ...................................68

6.9 Checking/Adjusting the Burner Air Band .............................................69

6.10 Checking/Adjusting the Burner Head ..................................................70

6.11 Checking/Setting the Fuel Pressure ....................................................71

6.12 Analyzing the Combustion ...................................................................72

7 Maintenance 73

7.1 Periodic Maintenance Schedule ..........................................................73

7.2 Inspecting and Lubricating the Blower Bearings .................................74

7.3 Cleaning the Blower Motor ..................................................................75

7.4 Inspecting the Blower Drive Belts ........................................................76

7.5 Inspecting the Blower Drive Pulleys ....................................................77

7.6 Servicing the Fuel-Water Separator ....................................................78

7.7 Inspecting the Heat Exchanger ...........................................................79

7.8 Storing the Machine ............................................................................87

7.9 Preparing the Machine for Seasonal Operation ..................................88

7.10 Connecting and Maintaining the Battery .............................................89

Table of Contents

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8 Genset Maintenance 90

8.1 Periodic Maintenance Schedule ......................................................... 90

8.2 Checking the Engine Oil ..................................................................... 92

8.3 Servicing the Fuel-Water Separator ................................................... 93

8.4 Changing the Engine Oil and Oil Filters ............................................. 94

8.5 Replacing the Engine Fuel Filter ........................................................ 96

8.6 Servicing the Radiator ........................................................................ 97

8.7 Servicing the Air Cleaner and the Air Filter ........................................ 99

9 Basic Troubleshooting 100

10 Technical Data 102

10.1 Machine ............................................................................................ 102

10.2 Dimensions ....................................................................................... 103

11 Schematics 104

11.1 AC Circuit ......................................................................................... 104

11.2 Wire Color Legend ........................................................................... 105

11.3 AC Circuit—Schematic Legend ........................................................ 105

11.4 DC Circuit ......................................................................................... 106

11.5 DC Circuit—Schematic Legend ........................................................ 107

11.6 Trailer Lights and Brakes — Wiring Diagram ................................... 108

11.7 Trailer Lights and Brakes — Components ....................................... 109

11.8 Trailer Plug — Wiring Diagram ......................................................... 109

11.9 Trailer Junction Box — Wiring Diagram ........................................... 110

Table of Contents

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HI 770XHD 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 HI 770XHD

1.2 Machine Description and Intended Use

The HI 770XHD Heaters are indirect-fired air heaters available in oil (diesel)

burning models. The machine consists of the following components:

 Combustion chamber and heat exchanger

 Centrifugal blower

 Single-stage burner

 High-temperature shut-down switch(es)

 Fuel tank

 Trailer

 Generator

Fuel is consumed in a closed combustion chamber. Outside air is pulled in by the

centrifugal blower and blown over the hot heat exchanger. This clean, dry, hot air is

then blown into the space to be heated by the centrifugal blower.

The HI 770XHD Heaters are intended to provide heat on construction sites 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.

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

 fuel and fuel fumes when refueling

 high voltages and arc flash

To protect yourself and others, thoroughly read and understand the safety

information presented in this manual before operating the machine.

Wacker Neuson offers many optional accessories for the machine. These

accessories include the following: (Contact your Wacker Neuson dealer for more

information.)

 Duct adapters (various sizes).

 Duct hose

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HI 770XHD 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

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.

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.

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Safety Information HI 770XHD

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

When operating the machine:

 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.

 Store the machine properly when it is not being used.

 Keep unauthorized personnel, children, and pets away from the machine.

When operating the machine:

 Do not connect ductwork between the exhaust outlet port and the supply air inlet

port.

 Do not position the electrical cords under the machine or over the top of the

machine.

DANGER

Exhaust gas from the genset engine and the burner contains carbon monoxide, a

deadly poison. Exposure to carbon monoxide can kill you in minutes.

f Never run the machine indoors or in an enclosed area.

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HI 770XHD Safety Information

1.4 Safety Guidelines for Operating Combustion Burners

Burner safety

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.

f Never run the machine indoors or in an enclosed area.

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Safety Information HI 770XHD

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 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.

 Reinstall 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.

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.

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15

HI 770XHD Safety Information

 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.

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).

Maintenance

guidelines

When maintaining the machine:

 Keep the fuel lines in good condition and properly connected.

 Allow the burner and the genset engine to cool before maintaining the machine.

 Reinstall 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.

Heat

exchanger

inspection

The heat exchanger must be inspected once a year to ensure it is in good working

order. Shorter inspection intervals are recommended for units operating under

extreme transportation or operating conditions.

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Safety Information HI 770XHD

1.6 Safety Guidelines for Operating Gensets

This machine is built with user safety in mind; however, like any electrical device it

can present serious hazards if improperly operated and serviced. Follow

instructions carefully. Should questions arise during operation or service of this

equipment, contact your Wacker Neuson dealer.

General

precautions

 Keep a multi-class, type ABC or equivalent fire extinguisher at hand when using

the genset. Refer to NFPA No. 10 for further information regarding fire

extinguishers.

 Do not use evaporative starting fluids. They are highly explosive.

 Do not store items such as excess oil, oil rags, or tools within the genset

compartment. Items stored within the genset compartment are a fire hazard and

can restrict cooling air.

Before

operating the

genset

 Know how to start, operate, and stop the genset before starting it.

 Obtain the proper training for operating the genset. Do not allow untrained

personnel to operate or service the genset.

 Check the fuel lines and the fuel tank for leaks and cracks before starting the

engine.

 Clean the genset of any spilled fuel.

DANGER

Carbon monoxide. Using a generator indoors CAN KILL YOU IN MINUTES. Gen-

erator exhaust contains carbon monoxide (CO). This is a poison you cannot see or

smell. If you can smell the generator exhaust, you are breathing CO. But even if

you cannot smell the exhaust, you could be breathing CO.

WARNING

Electrocution hazard. Generators present special hazards during operation and

servicing. These include the risk of electrocution or severe electrical shock. Failure

to follow the safety information below can result in severe injury or death.

f Read and follow the safety instructions in this Operator’s Manual.

f Read and follow the safety instructions in the Kubota engine operator’s manual

and the Marathon generator manual.

f Contact Kubota or Marathon for additional information regarding the genset.

WARNING

Internal combustion engines present special hazards during operation and fueling.

Failure to follow the warnings and safety instructions could result in severe injury or

death.

f Read and follow the safety instructions in this Operator’s Manual.

f Read and follow the safety instructions in the Kubota engine operator’s manual.

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17

HI 770XHD Safety Information

Running the

genset

 Do not start the engine if fuel has spilled or a fuel odor is present.

 Keep the area around the exhaust pipe free of flammable materials.

 Do not smoke while operating the genset.

 Keep sparks, flames, electrical arcs, and other sources of ignition far away from

the genset.

 Do not touch the engine or muffler while the engine is running or immediately

after it has been turned off.

 Do not overload the genset. The total amperage of the tools and equipment

attached to the genset must not exceed the load rating of the genset.

 Do not operate the genset with wet hands.

 Do not remove the radiator cap when the genset is running or is hot.

Refueling

safety

When adding fuel to the fuel tank:

 Do not smoke.

 Do not refuel a hot or running engine.

 Do not use diesel fuel that is mixed with gasoline or alcohol.

When adding fuel to the fuel tank:

 Keep sparks, flames, electrical arcs, and other sources of ignition far away from

the genset.

 Refill the fuel tank only in a well-ventilated area.

 Reinstall the fuel tank cap after refueling.

Maintenance

safety

 Only a trained technician should attempt to repair the genset.

 Test procedures which require that the generator be running must be performed

using extreme caution.

 Make sure clothing and shoes are dry, stand on a dry wooden platform or rubber

insulating mat, and use tools with insulated handles when servicing the genset.

 Engine antifreeze is toxic to humans and animals. Clean up spills and dispose

of used engine antifreeze in accordance with local environmental regulations.

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Safety Information HI 770XHD

1.7 Safety Guidelines for Towing the Machine

When towing the machine:

 Do not tow the machine if the towing vehicle’s hitch or the trailer’s coupler are

damaged.

 Do not tow the machine if any of the trailer’s lug nuts are missing.

 Do not tow the machine if the trailer’s tires have less than 1.5 mm (1/16 inch) of

tread.

 Do not tow the machine unless the trailer’s brakes are functioning properly.

 Do not exceed the trailer manufacturer’s speed limitations.

When towing the machine:

 Only tow the machine when the trailer’s lug nuts are properly torqued.

 Only tow the machine when the trailer’s tires are properly inflated.

 Only tow the machine when all trailer lights are functioning correctly.

 Only tow the machine when the trailer’s safety chains are connected to the

towing vehicle in a crisscross pattern.

 Maintain extra distance between the towing vehicle and other vehicles.

 Avoid soft shoulders, curbs, and sudden lane changes

 Abide by all licensing requirements for your area.

If you have not driven a towing vehicle with trailer before, practice turning,

stopping, and backing up the towing vehicle with trailer in an area away from traffic.

Only drive the towing vehicle with trailer when you are confident in your ability to do

so.

WARNING

Risk of severe injury or death. Improper trailer condition and towing technique can

lead to an accident.

f Obey the trailer manufacturer’s instructions and the instructions below to reduce

the risk of an accident.

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HI 770XHD Safety Information

1.8 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.

Labels HI 770XHD

20 wc_si000622gb.fm

2 Labels

2.1 Label Locations

135

116118

140

48

52

48

211

80

53

137137

64

118

136

46

164

137

167

166

999

64

135118 118

995

116

209

204

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HI 770XHD Labels

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2.2 Label Meanings

46

48 DANGER

Asphyxiation hazard.

Using this machine indoors CAN KILL YOU

IN MINUTES. Burner exhaust and generator

exhaust (if the machine is equipped with a

generator) contains carbon monoxide. This is

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.

26

—

27 Machine rating label: This label indicates rat-

ing information for the machine.

26 Machine rating label: This label indicates rat-

ing information for the machine.

For machines powered by

the generator:

Use a 50-50 blend of #2 diesel

and #1 diesel plus additives,

or a 50-50 blend of #2 diesel

and K1 kerosene plus addi-

tives when temperatures

are below 5°F (-15°C).

Use a 70-30 blend of #2 diesel and #1 diesel plus additives or

a 70-30 blend of #2 diesel and K1 kerosene plus additives

when temperatures are in the range 5 to 25°F (-15 to -4°C).

Use a winter-blend diesel when temperatures are above

25°F (-4°C).

For machines powered by

the power utility:

Use 100% #1 diesel plus

additives or 100% K1 kero-

sene plus additives when

temperatures are below

are below 5°F (-15°C).

wc_gr008377

Labels HI 770XHD

22 wc_si000622gb.fm

53 After burner shutdown, run blower until

temperature controller reads 37.7° C (100°

F) or lower.

64 Machine weight

65

Important:

Allow blower to run after burner is shut

down, to cool heat exchanger until

temperature control reads 37.7°C

(100°F) or lower.

Failure to do so could cause overheating

and failure of critical components.

80

HI 770XHD OPERATING GUIDE

NOTE: These instructions are intended to provide experienced operators quick

reminders of starting and shutdown procedures explained in detail in the

OPERATOR'S MANUAL. The OPERATOR'S MANUAL MUST BE READ and

UNDERSTOOD before operating this heater.

NOTE: These instructions are intended to provide experienced operators quick reminders of starting and shutdown procedures explained

in detail in the OPERATOR'S MANUAL. The OPERATOR'S MANUAL MUST BE READ and UNDERSTOOD before operating this heater.

HI770 XHD OPERATING GUIDE

STARTING GUIDE

1. Verify the following:

a. Fuel tank has adequate fuel.

b. EMERGENCY STOP button left of roller door is pulled OUT.

c. All control panel switches and circuit breakers are OFF.

2. Turn BATTERY switch ON (located beneath 12 VDC PANEL).

3. Turn ignition key switch to GLOW PLUG position. "GENERATOR GLOW

PLUGS" lamp should illuminate. Hold key switch in this position to heat

glow plugs according to guidelines below. If ambient temperatures are:

Above 40°F Hold for 10 seconds

Between 20 - 40°F Hold for 30 seconds

Below 20°F Hold for 60 seconds or more

4. Turn ignition key switch to RUN position.

5. While holding down LOW OIL PRESSURE OVERRIDE switch, turn

ignition key switch to START position. If engine does not

start after cranking for 20 seconds, repeat Steps 2 - 5.

6. Turn all 3 breakers ON: MAIN, BURNER, and OUTLET.

7. Verify TEMPERATURE CONTROL is set to desired output temperature.

8. Turn BLOWER switch ON.

SHUTDOWN GUIDE

1. Turn BURNER switch OFF.

2. IMPORTANT: Allow BLOWER to run after burner has shut down to cool

heat exchanger until TEMPERATURE CONTROL reads 100°F or lower.

3. Turn BLOWER switch OFF.

4. Turn all 3 breakers OFF: MAIN, BURNER, and OUTLET.

5. Turn ignition key switch counterclockwise to OFF.

6. Be sure all interior lights are switched OFF.

7. Turn BATTERY switch OFF (located beneath 12 VDC PANEL).

FOR EMERGENCY SHUTDOWN: Push EMERGENCY STOP button

ADDITIONAL NOTES

1. ALWAYS refer to the OPERATOR'S MANUAL when questions or

abnormal conditions arise.

2. Contact your dealer for any additional support required.

193349

9. Turn BURNER switch ON. Burner motor will start after 5 second

delay and fuel will be ignited after 6 second purge.

NOTE: If the machine has run out of fuel, the prime pump may

need pushing after refueling.

HI 770XHD Labels

wc_si000622gb.fm 23

STARTING GUIDE

1. Verify the following:

a. Fuel tank has adequate fuel.

b. EMERGENCY STOP button is

pulled OUT.

c. All control panel switches and

circuit breakers are OFF.

2. Turn BATTERY switch ON (located

beneath 12 VDC PANEL).

3. Turn ignition key switch to GLOW

PLUG position. "GENERATOR GLOW

PLUGS" lamp should illuminate. Hold

key switch in this position to heat glow

plugs according to guidelines below. If

ambient temperatures are:

Above 40°F: Hold for 10

seconds

Between 20-40°F: Hold for 30

seconds

Below 20°F: Hold for 60

seconds or more

4. Turn ignition key switch to RUN

position.

5. While holding down LOW OIL

PRESSURE OVERRIDE switch, turn

ignition key switch to START position.

If engine does not start after cranking

for 20 seconds, repeat Steps 2 - 5.

6. Turn all 3 breakers ON: MAIN,

BURNER, and OUTLET.

7. Verify TEMPERATURE CONTROL

is set to desired output temperature.

8. Turn BLOWER switch ON.

9. Turn BURNER switch ON. Burner

motor will start after 5 second delay

and fuel will be ignited after 6-second

purge. NOTE: If the machine has run

out of fuel, the prime pump may need

pushing after refuelling.

SHUTDOWN GUIDE

1. Turn BURNER switch OFF.

2. IMPORTANT: Allow BLOWER to run after

burner has shut down to cool heat exchanger until

TEMPERATURE CONTROL reads 100°F or

lower.

3. Turn BLOWER switch OFF.

4. Turn all 3 breakers OFF: MAIN, BURNER, and

OUTLET.

5. Turn ignition key switch counterclockwise to

OFF position.

6. Be sure all interior lights are switched OFF.

7. Turn BATTERY switch OFF (located beneath

12 VDC PANEL).

FOR EMERGENCY SHUTDOWN: Push

EMERGENCY STOP button

ADDITIONAL NOTES

1. ALWAYS refer to the OPERATOR'S MANUAL

when questions or abnormal conditions arise.

2. Contact your dealer for any additional support

required.

116 WARNING:

Lugnuts factory torqued to 110 ft.lbs. Verify

lugnuts are properly torqued before

transporting. Failure to heed above warning

could result in wheel loss which can cause

injury or death.

Labels HI 770XHD

24 wc_si000622gb.fm

118 Tie-down location marker.

135 Forklift lift point

136 CAUTION

This machine uses diesel fuel.

137 NOTICE!

Lift point.

Attach lifting device in this location.

140 CAUTION!

Hot surface hazard!

DIESEL

CAUTION

VORSICHT

PRECAUCION

CAUTION

VORSICHT

PRECAUCION

PRECAUTION

HI 770XHD Labels

wc_si000622gb.fm 25

164 Emergency stop

165

High limit safety shutdown (manual

reset).

This label informs the user of the location

of the high temperature safety shutdown

device (snap disc). This component must

be manually reset when tripped.

166

Generator auxiliary power output

(120VAC, 15A maximum).

This label informs the user of the location

and rating of the generator auxiliary

power output receptacle.

167 Power input (120VAC, 15A maximum).

This label informs the user of the location

and rating of the input power.

168

Auxiliary city power input (120 VAC, 15 A

maximum).

This label indicates the location and

rating of the auxiliary power receptacle.

204 Junction box wiring diagram showing trailer

side and plug side (vehicle side) wires.

The color of the wires used on the vehicle

may differ from those used on the trailer.

Labels HI 770XHD

26 wc_si000622gb.fm

209 WARNING!

Do not engage trailer jack while transporting

the machine.

Refer to the Operator’s Manual for further

instructions.

995 Never operate in an explosive environment

or near flammable vapors, fuels or

combustibles. Explosion or fire may occur.

Risk of severe injury or death.

998 (on trailer)

Tire and loading information label:

This label indicates tire and loading informa-

tion for the trailer.

(on trailer)

VIN label. This label displays vehicle identifi-

cation numbers and other related informa-

tion.

999 Machine rating label: This label indicates rat-

ing information for the machine.

WARNING

WARNUNG

ADVERTENCIA

AVERTISSEMENT

173200

5200002911

Never operate in an explosive environment or near flammable vapors, fuels

or combustibles. Explosion or fire may occur. Risk of severe injury or death.

Nunca opere en un ambiente explosivo o cerca de los vapores inflamables,

gasolina o combustibles. Explosión o un incendio puede ocurrir.

Riesgo de lesiones graves o la muerte.

Ne faire jamais fonctionner dans un environnement explosif ou à proximité

des vapeurs inflammables, des carburants ou combustibles. Explosion ou un

incendie peut se produire. Risque de blessures graves ou la mort.

WARNING

ADVERTENCIA

AVERTISSEMENT

The weight of cargo should never exceed 1843 lbs. (836 kg)

LT 235/85R16 (G) 110 PSI (758 kPa)

HI 770XHD Labels

wc_si000622gb.fm 27

xx

WARNING

Operation of this equipment may create

sparks that can start fires around dry

vegetation. A spark arrester may be

required. The operator should contact local

fire agencies for laws or regulations relating

to fire prevention requirements.

WARNING

Operation of This Equipment May Create Sparks That Can Start Fires Around Dry

Vegetation. A Spark Arrestor May be Required. The Operator Should Contact Local

Fire Agencies For Laws or Regulations Relating to Fire Prevention Requirements.

Per CAL. PRC. CODE

Lifting and Transporting HI 770XHD

28 wc_tx001881gb.fm

3 Lifting and Transporting

3.1 Lifting the Machine

Requirements

 Lifting equipment (crane, hoist, or fork truck) capable of supporting

3500 kg (7700 lbs.)

 Lifting hooks, chains, and shackles capable of supporting 3500 kg (7700 lbs.)

 Machine stopped and cooled.

Procedure

Follow the procedure below to lift the machine.

1. Attach the lifting equipment to all four lifting eyes (a) on the machine using

hooks, shackles, and chains OR insert the lifting forks at the labeled locations

(b) and skip to step 3.

2. Attach the other end of the chains to the lifting equipment.

3. Lift the machine a small distance.

4. Check for stability. If necessary, lower the machine, reposition the lifting device,

and lift the machine a small distance again.

5. Continue lifting the machine as necessary.

WARNING

Crushing hazard. You may be crushed if the lifting devices fail.

f Never stand under, or get onto, the machine while it is being lifted or moved.

f Use only the designated lifting points to lift the machine.

b

g

hi

g

r006954

WARNING

Crushing hazard. An unstable machine may cause the lifting devices to fail. You

may be crushed if the lifting devices fail.

f Check for stability before continuing.

HI 770XHD Lifting and Transporting

wc_tx001881gb.fm 29

3.2 Preparing the Machine for Transport on a Truck or Trailer

Requirements

 Machine stopped

 Flatbed truck or trailer capable of supporting the machine’s weight

 Chains, hooks, or straps capable of supporting the machine’s weight

Checklist

Before transporting the machine, check the following items:

Machine

 Check that all accessories are securely stored within the machine.

 Check that all doors and access panels of the machine are closed.

 Check that all electrical supplies are disconnected from the machine.

 For machines with external fuel supplies, check that all fuel supplies are

disconnected from the machine.

 For machines with generators, check that the generator is shut down.

Loading and transporting equipment

 Check that the transport vehicle or trailer can support the weight of the machine.

 Check that the transport vehicle or trailer is wide enough to support the

machine.

 Check that the wheels of the transport vehicle or trailer are chocked during the

loading process.

 Check that the transport vehicle or trailer is clean and free of grease, oil, ice,

and other loose material.

 If the machine is mounted to a trailer, check that the jackstand or other transport

block (piece of wood or other similar material) is available to support the trailer

tongue during transporting. Do not use the machine’s trailer jack to support the

trailer tongue during transporting.

 Check that any ramps used in the loading process:

 Can support the weight of the machine.

 Are clean and free of grease, oil, ice, and other loose material.

 Are securely connected to the transport vehicle or trailer.

 Are of sufficient length to keep the loading angle 15° or less.

In addition:

 Check that the loading area is flat and the ground is stable.

 Check the overall height of the machine once it is loaded on the truck or trailer.

Plan your travel route so there will be adequate clearance for overpasses, road

signs, buildings, etc.

 Check local regulations regarding transporting and obey these regulations.

WARNING

Crushing hazard. Improperly securing the machine can lead to a crushing hazard.

f Use only the designated tie-down points to secure the machine to a truck or

trailer.

Lifting and Transporting HI 770XHD

30 wc_tx001881gb.fm

3.3 Transporting the Machine on a Truck or Trailer

Requirements

 Machine stopped

 All doors and access covers closed and secured

 Properly-rated ramps or docks

 Properly-rated chains or straps

 Truck or trailer capable of supporting the machine’s weight

NOTICE: Do not run chains or straps across any painted surface. Failure to comply

may cause damage to your machine.

Procedure

Perform the procedure below to transport on a flat bed truck or trailer.

1. Move the machine onto the flat bed truck using properly-rated ramps or docks,

or by lifting it.

2. Install a support (a) under the trailer tongue.

3. Remove the trailer jack foot extension (b) and store for later use.

NOTICE: Do not use the trailer jack to support the machine during transport.

4. Secure the machine to the bed with properly-rated chains or straps (d).

5. Install chocks (e) under the wheels.

Result

The machine is ready to be transported.

WARNING

Crushing hazard. Improperly securing the machine can lead to a crushing hazard.

f Use only the designated tie-down points to secure the machine.

wc_gr008641

d

a e

HI 770XHD Lifting and Transporting

wc_tx001881gb.fm 31

3.4 Before Towing Checklist

Before towing the machine, check the licensing requirements for trailers in your

area. Also check the following items:

Hitch and coupler

 Check that the towing vehicle and hitch have a rating equal to or greater than

the GVWR of the machine. See Technical Da ta.

 Check that the hitch of the towing vehicle and coupler of the trailer are

compatible.

 Check the condition of both the coupler and the hitch.

 Check that all fasteners on the coupler are secure.

 Check that the coupler has fresh grease applied to it.

Wheels

 Check that all lug nuts are in place and are properly torqued.

 Check the tread wear of the tires.

 Check that the tires are inflated to the proper pressure.

Trailer operation

 Check that the directional and running lights on the trailer function correctly.

 Check that the safety chains of the trailer are connected to the towing vehicle

using a crisscross pattern.

 Check that the trailer’s breakaway cable is attached to the towing vehicle.

 Check the operation of the trailer brakes by braking the towing vehicle at a slow

speed. Both the vehicle and the trailer must brake smoothly. If the trailer

pushes, check the fluid level in the surge brakes or the operation of the electric

brakes.

 Test the function of the breakaway system.

Lifting and Transporting HI 770XHD

32 wc_tx001881gb.fm

3.5 Towing the Machine

NOTICE: The tow vehicle must be equipped with a Class III or above hitch.

Procedure

Perform the procedure below when towing the machine.

1. Read and follow the towing safety guidelines. See topic Safety Guidelines for

Towing the Machine.

2. Complete the shut-down procedures.

3. Adjust the amount of fuel in the machine to approximately 70% capacity to avoid

fuel spillage.

4. Complete the Before Towing Checklist. See topic Before Towing Checklist.

5. Connect the machine to the tow vehicle.

6. Connect the safety chains (a) to the tow vehicle in a crisscross pattern.

7. Connect the lighting cable (b) to the tow vehicle.

8. Connect the cable from the brake breakaway switch (c) to the tow vehicle.

9. Raise the trailer jack (d).

10.Tow the machine as needed.

WARNING

Risk of severe injury or death. Improperly torqued lug nuts can lead to loss of

wheels. Loss of wheels can cause an accident, severe injury, or death.

f Tighten the lug nuts to the proper torque before towing the machine.

wc_gr008652

a

b

c

d

HI 770XHD Lifting and Transporting

wc_tx001881gb.fm 33

3.6 Testing the Breakaway System (Electric Brakes)

Requirements

 Voltmeter

 Battery charger or backup battery (charged)

When

Test the breakaway system:

 Before towing

 Monthly if the machine is not in service

Procedure

Perform the following procedure to test the breakaway system.

NOTICE: Disconnect the trailer wiring plug from the tow vehicle before testing.

Failure to do so will result in severe damage to the electronic brake control.

1. Connect the machine/trailer to the tow vehicle.

2. Disconnect the trailer wiring plug (a) from the tow vehicle.

3. Pull the breakaway pin (b) out of the brake switch (c) (to activate the brakes)

and attempt to tow the machine/trailer at a very slow speed (less than 5 mph).

When activated, a properly working breakaway system will cause substantial

drag on the trailer wheels and may even cause the trailer wheels to lock.

4. Stop the tow vehicle.

This procedure continues on the next page.

wc_gr008513

a

wc_gr008514

b

c

WARNING

Personal injury hazard. A faulty breakaway system may lead to an accident and

personal injury if the machine/trailer breaks away.

f Do not tow the machine/trailer if the breakaway system is faulty.

Lifting and Transporting HI 770XHD

34 wc_tx001881gb.fm

Continued from the previous page.

5. If the brakes did not function, check the voltage of the breakaway battery.

To do so:

a. Remove the cover of the battery box.

b. Remove the wires connected to the breakaway battery (d).

c. Measure the voltage. If 12–14 VDC is not measured, replace or recharge the

breakaway battery.

6. If 12–14 VDC was measured but the brakes did not function, there is a wiring or

mechanical fault with the brakes. Repair any faults before towing.

7. If the brakes function properly:

a. Reconnect the wires to the breakaway battery.

b. Reinstall the cover to the battery box.

c. Reinstall the breakaway pin (b) into the brake switch.

d. Connect the trailer wiring plug to the tow vehicle.

Result

The procedure to test the breakaway system is now complete.

wc_gr008515

d

VDC

1000

200

20

2

200m

F

V

A

V- COM

HI 770XHD Operation

wc_tx001882gb.fm 35

4 Operation

4.1 External Components

wc_gr008664

a

b

d

h

i

j

k

e

f

g

l

c

Ref. Description Ref. Description

a

Heater exhaust

g

Air output (with duct adapter)

b

Burner access door

h

Emergency stop switch

c

Genset exhaust

i

Generator auxiliary power output

d

Genset compartment access door

j

Auxiliary city power input

e

Fuel tank access door

k

Cabin exhaust

f

Air intake port

l

Air vent

Operation HI 770XHD

36 wc_tx001882gb.fm

4.2 Burner Compartment Components

Ref. Description Ref. Description

a Heat exchanger h Burner fuel pump

b Burner fuel filter (with priming bulb

and water separator)

i Fuel gauge

c Snap disc switch

(210°F, manual reset)

j Burner ignition transformer

d Burner fuel pressure gauge k Burner primary control

e Burner l Burner blower motor

f Generator fuel pump m Generator fuel filter (with water

separator)

g Air pressure differential switch

(located behind item b)

n Kubota engine oil filters

wc_gr008665

a

b

c

d

e

g

h

k

j

l

i

f

m

n

HI 770XHD Operation

wc_tx001882gb.fm 37

4.3 Generator Compartment Components

Ref. Description Ref. Description

a 120/208VAC control panel f Marathon 3-phase generator

b 12 VDC control panel g Kubota engine oil reservoir

c Battery shut-off switch h Blower

d

Battery

i Kubota engine

e Auxiliary 120VAC outlet j Light

wc_gr008666

a

j

b

c

d

e

g

i

f

h

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