0170893en 006 0809 Indirect-fired Air Heaters Cub 200/300/300 HD OPERATOR’S MANUAL 0 1 7 0 8 9 3 E N
Foreword 1 Foreword WARNING 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. This manual provides information and procedures to safely operate and maintain this Wacker Neuson model. For your own safety and protection from injury, carefully read, understand and observe the safety instructions described in this manual.
Foreword Notes: wcghi_tx000001gb diesel.
Table of Contents 1. Foreword 3 2. Safety Information 7 2.1 2.2 2.3 2.4 2.5 3. Operation 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 4. Operating Safety .................................................................................. 7 Operator Safety while using Combustion Burners ............................... 8 Service Safety ...................................................................................... 8 Label Locations ...................................................
Table of Contents 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 5. Inspecting the Electrical Connections .................................................39 Fuel Blend Guide .................................................................................39 Transporting ........................................................................................40 List of Abbreviations ............................................................................41 Troubleshooting .....................................
Cub 200/300/300 HD 2 Safety Information Safety Information This manual contains DANGER, WARNING, CAUTION, NOTICE, and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
Safety Information Cub 200/300/300 HD 2.1.3 Keep unauthorized personnel, children, and pets away from the machine. 2.1.4 Always operate machine with all safety devices and guards in place and in working order. Do not modify or defeat safety devices. Do not operate machine if any safety devices or guards are missing or inoperative. 2.1.
Cub 200/300/300 HD Safety Information 2.3.1 ALWAYS replace the safety devices and guards after repairs and maintenance. 2.3.2 Keep the machine clean and labels legible. Replace all missing and hard-to-read labels. Labels provide important operating instructions and warn of dangers and hazards. 2.3.3 ALWAYS make sure slings, chains, hooks, ramps, jacks, and other types of lifting devices are attached securely and have enough weightbearing capacity to lift or hold the machine safely.
Safety Information 2.4 Cub 200/300/300 HD Label Locations wcghi_si000212gb.
Cub 200/300/300 HD 2.5 Ref. Safety Information Label Descriptions Label Label Text 1 Danger! Hazardous voltage. Do not operate without this cover in place. Disconnect and lock out power source before opening panel. Could cause severe injury or death. 2 Warning: Blower can automatically start which can cause serious injury. Disconnect power source before servicing. 3 WARNING Warning: Blower can automatically start which can cause serious injury. Disconnect power source before servicing.
Safety Information Ref. Label Cub 200/300/300 HD Label Text 4 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. 5 Warning: Electric shock hazard. Disconnect power before servicing. Read Operator’s Manual. 6 Danger: To avoid injury from moving parts, shut off the equipment before removing this cover.
Cub 200/300/300 HD Ref. Label Safety Information Label Text 10 Diesel fuel blend guide. This label indicates the recommended fuel blending values for diesel fuel usage. 11 Tie-down point. 12 Machine rating label: This label indicates rating information for the machine. 13 Weight/mass label: This label indicates the total weight of the machine, including the trailer and a full fuel tank.
Safety Information Ref. Label Cub 200/300/300 HD Label Text 15 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 number, item number, revision number, and serial number of the unit. 16 Schematic label.
Cub 200/300/300 HD 3 Operation Operation 3.1 System Description The Cub series Air Heater machines are indirect-fired air heaters. The Cub series Air Heater machines incorporate aluminized steel shells and heat exchangers. The machines run on three fuel options: diesel, Kerosene, or winter blend diesel (winter blend diesel is treated with anti-gelling conditioners for use in cold weather). The fuel is consumed in a closed combustion chamber. The exhaust gasses must be vented outdoors through a vent pipe.
Operation 3.3 Cub 200/300/300 HD System Component Locations Ref wcghi_tx000720gb.
Cub 200/300/300 HD 3.4 Operation Mounting the Handle and Base Assembly See graphics: wcghi_003991 and ghi_gr005319 The Cub series Air Heater machines are shipped partially assembled. Before operating either machine, use the following procedure to mount the handles and base assembly. This assembly includes the handle, base support, and wheels with axles. Note: There are pre-drilled bolt holes for all the components installed within this procedure.
Operation 3.5 Cub 200/300/300 HD Machine Location The Air Heater machines may be located outdoors or in any environment that requires heating. When locating a machine within the area to be heated, the exhaust gases must be vented to the outdoors. The machines must be installed: • By qualified personnel who have read and understood all supplied instructions. • On a flat, firm surface. • With the following minimum clearances: • 3.05 m (10 ft.) to front. • 0.61 m (2 ft.) to rear. • 0.61 m (2 ft.
Cub 200/300/300 HD WARNING Exhaust gas from this machine CAN KILL YOU IN MINUTES. The exhaust contains carbon monoxide, a deadly poison you can not see or smell. This machine must be properly vented to reduce the risk of carbon monoxide poisoning. • wcghi_tx000720gb.fm Operation The above venting diagram shows suggested venting layouts only. Consult all appropriate governing bodies or local contractor for venting and fresh air requirements.
Operation 3.7 Cub 200/300/300 HD Connecting Power to the Machine WARNING Fire and electric shock hazard. High voltage can cause severe injury or death. This unit must be electrically grounded. Do NOT use adapters. The Air Heater machines come equipped with power cords. Connect the power cord to a grounded outlet rated for 115V, 60 Hz, 15A. 3.8 Preliminary Checks Before starting the machine, check the following: wcghi_tx000720gb.fm • Fuel supply on diesel burning machines. See Fuel Blend Guide.
Cub 200/300/300 HD 3.9 Ref Operation Control Panel Component Function a Remote thermostat receptacle The remote thermostat receptacle (shown with protective cap installed) is used for connecting an optional remote thermostat b Burner fault lamp and reset button (dual function). The dual function burner fault lamp and reset button: • illuminates red when the burner has faulted. • resets the machine when pressed. c Power switch The power switch provides power to the machine.
Operation Cub 200/300/300 HD 3.10 Starting the Machine 3.10.1 Perform the necessary preliminary checks. See section Preliminary Checks. 3.10.2 If using the remote thermostat, connect it to the control panel at the remote thermostat receptacle. Place the remote thermostat in the area to be heated. Set it to the desired temperature. Note: If the ambient temperature is below 32°F (0°C), it may be necessary to preheat the fuel. See section Preheating the Fuel Filter and Nozzle Heater. 3.10.
Cub 200/300/300 HD Operation 3.11 Starting the Machine in (Extreme) Cold Weather In temperatures below 32°F (0°C), it may be necessary to preheat the fuel inside the fuel filter canister. The fuel filter and nozzle contain lowwattage heating elements that are controlled by a thermostat and are specifically designed for this purpose. Hot surface hazard. The external surface of the fuel filter may be hot. CAUTION • Wear safety gloves when handling the fuel filter.
Operation Cub 200/300/300 HD 3.12 Shutting Down the Machine WARNING Electric shock and cutting injury hazard! At temperatures above 104°F (40°C), electric power is available at the supply blower even with the operation mode switch in the OFF position. Always remove all power to the machine before servicing it. 3.12.1 Move the power switch to the Off (“O”) position.
Cub 200/300/300 HD Operation 3.13 Using the Remote Thermostat See Graphic: wcghi_gr004009 In order for the machine to function, the remote thermostat (b) or the receptacle cover (a) must be installed into the control panel. To use the remote thermostat: 3.13.1 Plug (c) the remote thermostat into the control panel. 3.13.2 Set the sensor end within the space to be heated. 3.13.3 Adjust the temperature setting with dial (d). wcghi_tx000720gb.
Operation Cub 200/300/300 HD Notes: wcghi_tx000720gb.
Cub 200/300/300 HD 4 Maintenance Maintenance 4.1 Periodic Maintenance Schedule Prior to first seasonal use As needed or during regular maintenance Every 1200 hours or yearly Replace the burner nozzle Replace the fuel filter Inspect the burner electrodes Inspect and clean the Cadmium (CAD) cell.
Maintenance 4.2 Cub 200/300/300 HD Removing and Installing the Burner Assembly See graphic: wcghi_gr004015 Before performing any maintenance on the burner assembly, it must be removed from the machine. To remove or install the burner assembly perform the following procedure: Removal: 4.2.1 Shut down the machine and allow it to cool. 4.2.2 Disconnect the power cord from the power source. 4.2.3 Remove the two bolts (a) and open the access panel. 4.2.
Cub 200/300/300 HD wcghi_tx000721gb.
Maintenance 4.3 Cub 200/300/300 HD Replacing the Burner Nozzle See Graphic: wcghi_gr004016 To replace the burner nozzle, carry out the following procedure: Removal: 4.3.1 Remove the burner. See section Removing and Installing the Burner Assembly. 4.3.2 Place an adjustable wrench on the large fitting (1) on the nozzle base (3). 4.3.3 Place another adjustable wrench on the nozzle (2). 4.3.4 Rotate the nozzle counter-clockwise and remove it from the assembly. Installation: 4.3.
Cub 200/300/300 HD 4.4 Maintenance Replacing the Fuel Filter See Graphic: wcghi_gr004019 Hot surface hazard. The external surface of the fuel filter may be hot. CAUTION • Allow the machine to cool before servicing. • Wear safety gloves. Hot fluids. The fuel inside the filter canister may be hot. WARNING • Allow the machine to cool before servicing. • Wear safety glasses. To replace the fuel filter (b), carry out the following procedure. Removal: 4.4.1 Shut down the machine and allow it to cool.
Maintenance 4.5 Cub 200/300/300 HD Inspecting and Aligning the Burner Electrodes See graphic: wcghi_gr004020 To inspect and align the burner electrodes, carry out the following procedure. Inspection: 4.5.1 Remove the burner assembly. See section Removing and Installing the Burner Assembly. 4.5.2 Inspect the electrodes for the following: • Wear. Be sure to inspect the ends of the electrodes for pitting. Replace any worn electrodes. See section “Replacement or Alignment”. • Straightness.
Cub 200/300/300 HD 4.6 Maintenance Inspecting and Cleaning the Cadmium (CAD) Cell See Graphic: wcghi_gr004021 To inspect and clean the CAD cell, carry out the following procedure. 4.6.1 Remove the burner assembly. See section Removing and Installing the Burner Assembly. 4.6.2 Twist and pull out the plastic protective holder (1) off the base of the burner assembly. The CAD cell is inside this plastic holder. 4.6.3 Inspect the CAD cell for the following: • 4.6.4 Cleanliness.
Maintenance 4.7 Cub 200/300/300 HD Checking and Adjusting the Fuel Pressure See Graphic: wcghi_gr004025 To check the fuel pressure a pressure gauge is needed. To check and/ or adjust the fuel pressure, carry out the following procedure: 4.7.1 Shut down the machine and allow it to cool. 4.7.2 Disconnect the power cord from the power source. 4.7.3 Remove the two bolts (a) and open the access panel. 4.7.4 Remove the threaded plug (b) from the pressure test port using an allen wrench.
Cub 200/300/300 HD wcghi_tx000721gb.
Maintenance 4.8 Cub 200/300/300 HD Cleaning the Fan Blades and Motor See graphic: wcghi_gr004030 To clean the fan blades and motor, carry out the following procedure: 4.8.1 Shut down the machine and allow it to cool. 4.8.2 Disconnect the power cord from the power source. 4.8.3 Remove the fan guard. There are four screws that secure the guard. 4.8.4 Remove the six bolts that secure the top portion of the shell. 4.8.5 Remove the top shell to access the interior of the machine. 4.8.
Cub 200/300/300 HD 4.9 Maintenance Cleaning the Interior Shell See graphic: wcghi_gr004029 To clean the interior shell, carry out the following procedure: 4.9.1 Shut down the machine and allow it to cool. 4.9.2 Disconnect the power cord from the power source. 4.9.3 Remove the fan guard. There are four screws that secure the guard. 4.9.4 Remove the six bolts that secure the top portion of the shell. 4.9.5 Remove the top shell to access the interior of the machine. 4.9.
Maintenance Cub 200/300/300 HD 4.10 Inspecting the Flame Head See Graphic: wcghi_gr004028 To inspect the flame head, carry out the following procedure: 4.10.1 Remove the burner assembly. See section Removing and Installing the Burner Assembly. 4.10.2 Mark the location of the air lock sleeve (c) with a pencil. 4.10.3 Loosen the wing nut (b). 4.10.4 Loosen the four screws (a) that secure the flame head (d). 4.10.5 Turn the flame head (d) counter-clockwise and remove. 4.10.
Cub 200/300/300 HD Maintenance 4.11 Inspecting the Electrical Connections After disconnecting the power cord, check all electrical connections for the following: • Proper connections. Be sure that all connections are complete and tight. • Corrosion. Clean or replace if necessary. • Damaged wires/connectors. Replace if necessary. • Proper ground. 4.
Maintenance Cub 200/300/300 HD 4.13 Transporting Cub series Air Heater machines must be supported by use of blocks during transport. NOTICE: DO NOT strap or chain down the unit with the foot or wheels in contact with the transporter. wcghi_tx000721gb.fm • Openings or the entire unit should be covered during transport to avoid road debris and clutter. • Take care when placing straps on areas which are painted red. Use corner protectors and never use chains.
Cub 200/300/300 HD Maintenance 4.14 List of Abbreviations Amp ampere (unit of electrical current) asl above sea level BTU British Thermal Unit °C Celsius (metric unit of temperature) °F Fahrenheit (unit of temperature) ft2 square foot/square feet (measurement of area) ft.lbs. foot pounds (unit of torque) gph gallons per hour (unit of liquid flow) GFI Ground Fault Interrupt(er) (protection device) Hz Hertz (unit of frequency) ID inner diameter in.
Maintenance Cub 200/300/300 HD 4.15 Troubleshooting Note: The following symptoms and remedies are some of the more common issues that have arisen during the history of these machines. These do not represent all the possibilities. If you need advanced troubleshooting assistance, please contact Wacker Neuson Product Support. Symptom Possible Causes Remedy The burner does not start • The remote thermostat or thermostat plug is not inserted correctly.
Cub 200/300/300 HD Maintenance Notes: wcghi_tx000721gb.
Maintenance Cub 200/300/300 HD 4.16 Cub 200/300 Wiring Schematic 4.17 Cub 300 HD Wiring Schematic wcghi_tx000721gb.
Cub 200/300/300 HD Maintenance 4.18 Schematic Legend Ref. wcghi_tx000721gb.fm Description Ref.
Maintenance wcghi_tx000721gb.
Cub 200/300/300 HD 5 Technical Data Technical Data 5.1 Machine Technical Data Item Number Model 0620204 0620262 Cub 200 0620233 Cub 300 0620253 Cub 300 HD Units Heat input BTU/hr 180,000 289,000 289,000 Heat output BTU/hr 147,000 232,000 232,000 1300 2600 2600 4.85 (1.28) 7.72 (2.04) 7.72 (2.04) 1.5-80 1.35-80 81.5 80 80 73 71 73.9 (at 3 m) 115/60 115/60 115/60 12 14 116.
Technical Data wcghi_td000213gb.
Wacker Neuson SE · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02-0 · Fax: +49 - (0)89-3 54 02-390 Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957 Wacker Neuson Limited - Room 1701–03 & 1717–20, 17/F. Tower 1, Grand Century Place, 193 Prince Edward Road West, Mongkok, Kowloon, Hongkong.
