Repair Manual Indirect-Fired Air Heater Cub 200 Cub 300 0179422en 0 1 7 9 001 4 2 1009 2 E N
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Cub 200/300 Foreword Foreword Machines covered by this manual Machine documentation Expectations for information in this manual Machine Item Number Machine Item Number Cub 200 0620204 Cub 300 0620233 Cub 200 0620262 — — 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.
Foreword ghi_tx001204gb.
Cub 200/300 1 Safety Information 1.1 1.2 1.3 1.4 1.5 2 7 Signal Words Found in this Manual ...................................................... 7 Safety Guidelines for Operating the Machine ....................................... 8 Safety Guidelines for Lifting the Machine ............................................. 9 Safety Guidelines While Using Combustion Burners ......................... 10 Safety Guidelines for Maintaining the Machine .................................. 11 Operation 2.1 2.2 2.
Table of Contents 6 Troubleshooting the Burner 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 7 Cub 200/300 37 Checking the Ignition Transformer ......................................................39 Checking the Cad Cell .........................................................................42 Checking the Fuel Filter Heater ...........................................................44 Checking Output Voltage from the Control Board ...............................46 Checking the Air Pressure Switch ......
Cub 200/300 1 1.1 Safety Information Safety Information Signal Words Found in this Manual 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.
Safety Information 1.2 Cub 200/300 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 Corporation for additional training if necessary. When operating this machine: Do not allow improperly trained people to operate the machine.
Cub 200/300 Safety Information When operating the machine: Do not connect ductwork between the exhaust outlet port and the supply air inlet port. Never operate the machine in areas that contain flammable objects, fuels, or products that produce flammable vapors. Do not position the electrical cords under the machine or over the top of the machine. 1.
Safety Information 1.4 Cub 200/300 Safety Guidelines While Using Combustion Burners When using the machine: Clean up any spilled fuel immediately. Replace the fuel tank cap after refueling the machine. Refill the fuel tank in a well-ventilated area. Shut down the generator, if equipped, when refueling. When using the machine: DANGER Exhaust gas from the burner contains carbon monoxide, a deadly poison. Exposure to carbon monoxide can kill you in minutes.
Cub 200/300 1.5 Safety Information Safety Guidelines for Maintaining the Machine Training 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.
Operation 2 2.1 Cub 200/300 Operation Controls and Components Ref ghi_tx001205gb.
Cub 200/300 2.2 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 2.3 Cub 200/300 Starting/Stopping the Machine If not using the remote thermostat Turning ON 1. Move the power switch (c) to the ON “I” position. The blower will turn on immediately. The burner will go through a prepurge cycle and then ignite. The burner will continue to fire and the blower will continue to operate until the machine is turned off. Turning OFF 2. Move the power switch to the OFF position. The burner will shut down.
Cub 200/300 Operation Notes ghi_tx001205gb.
Burner Setup 3 Cub 200/300 Burner Setup 3.1 Periods Control Board Sequence of Operation The burner controller has several periods it sequences through during normal operation. These periods are described below. . Period Action or Function Prepurge (T1) As soon as the control switch (SW) is turned ON, the prepurge period begins. It lasts approximately 10 seconds. During this period: The fan blows air into the combustion chamber to expel any residual exhaust gases.
Cub 200/300 Burner Setup Period Action or Function Operation (T3) After the ignition period, the operation period begins. It will last as long as there is flame or until the heater is turned off. During this period: The fan runs. The ignition transformer (TR) is OFF. There is no spark across the electrodes. The fuel solenoid (SV) is open and flame is self-sustaining. The cad cell (PH) monitors the flame.
Burner Setup 3.2 Cub 200/300 Setting Up the Burner Factory settings Background Fuel Machine Nozzle size Fuel pressure gph psi bar Air band setting Cub 200 1.0 x 60°A 175 12 2 Cub 300 1.5 x 80°W 175 12 3 Cub 300HD 1.35 x 80°H 218 15 5 The burner consists of several different components and subsystems. Each of these components or subsystems must be operating correctly for the burner to function properly. Low ambient temperatures cause diesel fuels to gel.
Cub 200/300 Burner Setup Continued from the previous page. When Adjust the burner: Before operating the machine at elevations 305 m (1,000 ft) above or below the location of where the last adjustments were made Before starting at a new job site After any burner maintenance or repair has been performed If burner performance is in question Procedure Follow the procedure below to set up the burner. 1. Shut down the machine. 2. Set the burner electrodes. (See Section 3.
Burner Setup Cub 200/300 Continued from the previous page. 8. Analyze the combustion. Follow the combustion analyzer manufacturer’s instructions and the general guidelines below. Use the access hole in the exhaust stack. Take several samples as the heater warms. Take the final sample just before the heater reaches 71°C (160°F). 9.
Cub 200/300 3.3 Burner Setup Removing and Installing the Burner Assembly Background Before performing any maintenance on the burner assembly, it must be removed from the machine. Removal To remove or install the burner assembly perform the following procedure: 1. Shut down the machine and allow it to cool. 2. Disconnect the power cord from the power supply. 3. Remove the two bolts and open the access panel (a). 4.
Burner Setup 3.4 Cub 200/300 Checking and Adjusting the Burner Electrodes Requirements Burner assembly removed Background Inspect the electrodes for the following: Wear Be sure to inspect the ends of the electrodes for pitting. Replace any worn electrodes. Straightness Replace any bent or broken electrodes. Cleanliness Clean the electrodes with a soft dry cloth or replace if necessary. Correct alignment Align the electrodes as shown.
Cub 200/300 3.5 Burner Setup Checking and Replacing the Burner Nozzle Requirements Burner assembly removed Removal Perform the procedure to remove the nozzle. 1. Remove the burner assembly. See topic Removing and Installing the Burner Assembly. 2. Place an adjustable wrench on the large fitting (1) on the nozzle base (3). 3. Place another adjustable wrench on the nozzle (2). 4. Rotate the nozzle counter-clockwise and remove it from the assembly.
Burner Setup 3.6 Cub 200/300 Setting the Air Band Requirements Procedure Machine shut down Power disconnected Perform the procedure below to set the air band. 1. Shut down the machine and allow it to cool. 2. Disconnect the power cord from the power source. 3. Remove the two bolts and open the access panel (a). 4. Loosen the wing nut (b) and slide the air band (c) as needed. The front edge should line up with the graduations (markings) on the flame head (d). 5. Tighten the wing nut.
Cub 200/300 3.7 Burner Setup Checking and Adjusting the Fuel Pressure Requirements Procedure Pressure gauge British Parallel Thread (BPT) adapter To check and/or adjust the fuel pressure, carry out the following procedure: 1. Shut down the machine and allow it to cool. 2. Disconnect the power cord from the power source. 3. Open the access panel (a). b ghi_gr006919 4. Remove the threaded plug (b) from the pressure test port using an allen wrench.
Burner Setup Cub 200/300 Continued from the previous page. 9. Adjust the fuel pressure, if necessary, using the adjusting screw (e). NOTICE: Do not adjust the fuel pressure outside of the parameters listed in the Technical Data charts. 10.Restart the machine and check the gauge. 11.Repeat steps 7–9 as necessary until the pressure is correct. 12.Remove the pressure gauge (d) from the pressure test port. 13.Reinstall the threaded plug (b) into the pressure test port. 14.
Cub 200/300 4 Troubleshooting Basics Troubleshooting Basics Where to Begin Procedure Perform the procedure below to determine where to begin. 1. Connect the power cord to a 120 VAC power supply. 2. Turn the machine on. If Then The blower runs, the problem is with the burner system. See Chapter 6 Troubleshooting the Burner. The blower does not run, the problem is with the blower system. See Chapter 5 Troubleshooting the Blower. The motor hums, the problem is with the starter capacitor.
Troubleshooting the Blower 5 Cub 200/300 Troubleshooting the Blower Best practice The best practice when troubleshooting this system is to: 1. Isolate and check each component of this system individually. 2. When a malfunctioning component is found, repair or replace it. 3. After replacing a malfunctioning component, retry system operation. This chapter provides procedures to check the components. Sequence When troubleshooting the blower, do so in the following sequence. Step Task See Topic 1.
Cub 200/300 5.1 Troubleshooting the Blower Checking the Fuse Requirements 120V power source Procedure Perform the procedure below to check the fuse. 1. Connect the power cord to a 120 VAC power supply. 2. Observe the green light (x). Does the green light illuminate? Yes ____ No ____ The fuse is OK. Continue. 3. Disconnect the power cord from the electric power supply. WARNING Electric shock hazard. High voltage exists inside the control panel when the power cord is plugged into a power supply.
Troubleshooting the Blower Cub 200/300 Continued from the previous page. 5. Remove the cover (b) from the control panel. 6. Locate the fuse (c) and check its condition. 7. Replace the fuse if it is blown with a fuse of the same size and rating. Result The fuse has now been checked. If the problem has not been resolved, leave the machine disassembled and continue with the next topic. Otherwise, reassemble the machine. 30 ghi_tx001207gb.
Cub 200/300 5.2 Troubleshooting the Blower Checking Power to/from the Control Board Requirements Procedure 120 VAC power source Multimeter Machine’s fuse is OK Perform the procedure below to check power to/from the control board. WARNING Electric shock hazard. High voltage exists inside the control panel when the power cord is plugged into a power supply. Electric shock can cause serious injury or death.
Troubleshooting the Blower Cub 200/300 Continued from the previous page. 5. Measure the voltage between terminal M8 and terminal M11 on the control board. Is 108–132 VAC measured? Yes ____ No ____ Continue. Disconnect the power supply. Check the function of the ON-OFF switch and the wiring to the ON-OFF switch. 6. Measure the voltage between terminal M15 and terminal M14. Is 108–132 VAC measured? Yes ____ No ____ The power to and from the control board is OK. Result The control board has failed.
Cub 200/300 5.3 Troubleshooting the Blower Checking the ON-OFF Switch Requirements Procedure Electric power disconnected from the machine Multimeter Perform the procedure below to check the ON-OFF switch. 1. Disconnect the power cord from the power supply. WARNING Electric shock hazard. High voltage exists inside the control panel when the power cord is plugged into a power supply. Electric shock can cause serious injury or death.
Troubleshooting the Blower Cub 200/300 Continued from the previous page. 6. Check that there is continuity between the two terminals where the black and brown wires are connected. There should be continuity when in the ON position and no continuity in the OFF position. Does the ON-OFF switch perform as described above? Result Yes ____ No ____ The ON-OFF switch is OK. The ON-OFF switch has failed; replace it. The ON-OFF switch has now been checked.
Cub 200/300 5.4 Troubleshooting the Blower Checking the Capacitor Requirements Procedure Power disconnected Multimeter Perform the procedure below to check the capacitor. 1. Disconnect the power cord from the electric power supply. WARNING Electric shock hazard. High voltage exists inside the machine when the power cord is plugged into a power supply. Electric shock can cause serious injury or death. f Disconnect the machine from the electric power supply before continuing this procedure. 2.
Troubleshooting the Blower Cub 200/300 Continued from the previous page. Does the capacitor measure 45–55 µF? Yes ____ No ____ Continue. The capacitor has failed; replace it. 6. If the capacitor checks OK but the motor still hums, the problem is with the wiring from the motor to the capacitor. Check this wiring. 7. If the capacitor and the wiring check OK but the motor does not run, the motor has failed. Replace the motor. Result The capacitor has now been checked. Reassemble the machine.
Cub 200/300 6 Troubleshooting the Burner Troubleshooting the Burner Background The two sources of flame problems are: Fuel Ignition Note: Make sure the blower runs before troubleshooting burner problems. If the blower does not run, the burner will not fire. See topic Troubleshooting the Blower. Procedure Perform the procedure below to determine if the problem is with the fuel system or with the ignition system. 1. Turn the machine on.
Troubleshooting the Burner Cub 200/300 Continued from the previous page. Fuel problems For fuel system problems, check the following items in the sequence listed. Order Component See topic 1. Fuel tank/supply n/a 2. Fuel filter n/a 3. Air band setting 3.6 3. Fuel filter heater 6.3 4. Fuel pressure 3.7 Depending on the results of the fuel pressure, continue with the appropriate sequence below.
Cub 200/300 6.1 Troubleshooting the Burner Checking the Ignition Transformer Requirements Fuel solenoid disconnected Procedure Perform the procedure below to check the ignition transformer. 1. Begin this procedure with the power supply disconnected. 2. Open the access panel (a). 3. Locate the fuel solenoid (b) and disconnect it. 4. Loosen the wingnut (e) and open the air lock as far as possible. 5. Connect the power supply. 6. Turn the machine on and observe the spark between the electrodes (f).
Troubleshooting the Burner Cub 200/300 Continued from the previous page. 7. Turn the machine off. 8. Remove the screws (c) that hold the control panel and pull the control panel from the machine. 9. Remove the cover (d) from the control. WARNING Electric shock hazard. High voltage exists at the control panel when the machine is turned on. Electric shock can cause severe injury or death. f Use extreme care and appropriate arc flash protective measures when working inside the machine. 10.
Cub 200/300 Troubleshooting the Burner Continued from the previous page. 12.Turn the machine off. 13.Check the condition of the ignition wires (g) between the transformer (h) and the flame head (i). If the ignition wires are damaged, replace them. 14.Check the resistance of the ignition wires. They should measure approximately 1000 ohms. If the ignition wires measure OL, replace them. Result ghi_tx001207gb.fm The procedure to check the ignition transformer is now complete. Reassemble the machine.
Troubleshooting the Burner 6.2 Cub 200/300 Checking the Cad Cell Requirements Procedure Power disconnected from the machine Multimeter Perform the procedure below to check the cad cell. 1. Disconnect the power cord from the power supply. 2. Open the access panel (a). 3. Twist and pull the cad cell (b) from the flame head. 4. Remove the screws (c) that hold the control panel and pull the control panel from the machine. 5. Remove the cover (d) from the control panel.
Cub 200/300 Troubleshooting the Burner Continued from the previous page. 6. Disconnect the light green wires (e) from terminals M5 and M6 of the burner controller. 7. Measure the resistance of the cad cell by measuring across the light green wires. Be sure the cad cell is exposed to light. Note: The resistance value will vary depending on the amount of light the cad cell receives. Is 1000–5000 ohms measured? Yes ____ Continue. No ____ The cad cell is dirty or defective.
Troubleshooting the Burner 6.3 Cub 200/300 Checking the Fuel Filter Heater Requirements Procedure Multimeter Electric power disconnected from the machine Perform the procedure below to check the fuel filter heater. 1. Turn on the machine. 2. Wait 10–15 minutes, then feel the outside of the fuel filter canister (c). Is the fuel filter canister warm to the touch? Yes ____ No ____ The fuel filter heater is working. No further testing is needed. Continue. 3.
Cub 200/300 Troubleshooting the Burner Continued from the previous page. 6. Check that the fuel heater is connected to terminals M7 and M12 of the control board. WARNING Electric shock hazard. High voltage exists inside the control panel when the power cord is plugged into a power supply. Electric shock can cause serious injury or death. f Use extreme care and appropriate arc flash avoidance techniques when performing this procedure. 7. Connect the power cord to the power supply. 8. Turn on the machine.
Troubleshooting the Burner 6.4 Cub 200/300 Checking Output Voltage from the Control Board Requirements Multimeter Procedure Perform the procedure below to check output voltage from the control board for the fuel system. 1. Start this procedure with the machine disconnected from the power supply. 2. Remove the screws (a) that hold the control panel and pull the control panel from the machine. 3. Remove the cover (b) from the control panel. WARNING Electric shock hazard.
Cub 200/300 Troubleshooting the Burner Continued from the previous page. 6. Measure the voltage between terminal M13 and terminal M18. To do so, you must wait through the 10-second prepurge cycle. Note: The voltage will only be present for approximately 1 second if the flame is not established. In such a case, the machine will go into a fault condition. It may take more than one attempt to measure the voltage. Is 108–132 VAC measured? Yes ____ No ____ The outgoing power from the control board is OK.
Troubleshooting the Burner 6.5 Cub 200/300 Checking the Air Pressure Switch Requirements Multimeter Procedure Perform the procedure below to check the air pressure switch. 1. Start this procedure with the machine disconnected from the power supply. 2. Remove the side access panel (a) from the machine. 3. Locate the air pressure switch (b) and check the air hose for binding, pinching, or damage. WARNING Electric shock hazard.
Cub 200/300 Troubleshooting the Burner Continued from the previous page. Is 108–132 VAC measured? Yes ____ No ____ Continue. The wiring between the control board and the air pressure switch has failed. Shut down the machine and check this wiring. 6. Turn the machine off. 7. Disconnect the wiring from the air pressure switch. 8. With the machine off, check the continuity between the terminals of the air pressure switch as shown.
Troubleshooting the Burner Cub 200/300 Continued from the previous page. 10.With the machine on, check the continuity between the same terminals of the air pressure switch. Is there continuity? Yes ____ No ____ The air pressure switch is OK. The air pressure switch has failed. Shut down the machine and replace the air pressure switch. 11.Turn the machine off. 12.Reinstall the wires. Result The air pressure switch has now been checked.
Cub 200/300 6.6 Troubleshooting the Burner Checking the Fuel Solenoid Requirements Procedure Multimeter Air pressure switch checks OK Perform the procedure below to check the fuel solenoid. 1. Turn the machine off. 2. Open the access panel (a). 3. Locate the fuel solenoid (b) and disconnect it. WARNING Electric shock hazard. High voltage exists at the fuel solenoid and other components inside the machine when the machine is turned on.
Troubleshooting the Burner Cub 200/300 Continued from the previous page. 4. Turn the machine on. If the machine is in a fault condition, press the RESET (c) button on the control panel. 5. Measure the voltage at the connector (d). To do so, you must wait through the 10-second prepurge cycle. Note: The voltage will only be present for approximately 1 second after the prepurge cycle ends. It may take more than one attempt to measure the voltage. Is 108–132 VAC measured? 6.
Cub 200/300 Troubleshooting the Burner Continued from the previous page. 7. Measure the resistance across the coil of the solenoid as shown. Is 600–700 ohms measured? Result ghi_tx001207gb.fm Yes ____ No ____ The fuel solenoid is OK. The fuel solenoid has failed; replace it. The fuel solenoid has now been checked. If the problem has not been resolved, leave the machine disassembled and continue with the next topic. Otherwise, reassemble the machine.
Troubleshooting the Burner 6.7 Cub 200/300 Checking the Flame Head Requirements Procedure Power disconnected Hand tools Perform the procedure below to check the flame head. 1. Disconnect the power cord from the power supply. WARNING Electric shock hazard. High voltage exists inside the machine when the power cord is plugged into a power supply. Electric shock can cause serious injury or death. f Disconnect the machine from the electric power supply before continuing this procedure. 2.
Cub 200/300 6.8 Troubleshooting the Burner Checking the Fuel Flow from the Nozzle Requirements Container to catch fuel (5 gallon bucket) Procedure Perform the procedure below to check the fuel flow from the nozzle. 1. Disconnect the power cord from the power supply. WARNING Electric shock hazard. High voltage exists inside the machine when the power cord is plugged into a power supply. Electric shock can cause serious injury or death.
Troubleshooting the Burner Cub 200/300 Continued from the previous page. 6. Connect the machine to the power supply. WARNING Fire hazard. The fuel may ignite if there is an ignition source nearby. Fire can cause severe injury or death. f Continue this procedure only when all sources of ignition have been removed from the proximity of the machine. 7. Hold the nozzle assembly facing into a container to catch the fuel spray. 8. Turn the machine on.
Cub 200/300 6.9 Troubleshooting the Burner Checking the Fuel Lines Requirements Procedure Machine turned off Power supply disconnected Perform the following procedure to check the fuel lines. 1. Turn the machine off. 2. Inspect the fuel lines (a) for leakage and loose fittings. 3. Repair or replace the fuel lines as needed. Result ghi_tx001207gb.fm The fuel lines have now been checked. If the problem has not been resolved, continue with the next topic.
Troubleshooting the Burner 6.10 Cub 200/300 Checking the Fuel Pump Adapter Requirements Procedure Machine turned off Power supply disconnected Perform the following procedure to check the fuel pump adapter. 1. Turn the machine off. 2. Open the access panel (a). 3. Locate the fuel pump (b). 4. Loosen the three set screws (c). 5. Remove the fuel pump (b) from the motor. 6. Check the fuel pump adapter (d) and replace the fuel pump adapter if it is damaged.
Cub 200/300 7 7.1 Schematic Schematic Cub 200/Cub 300 Schematic ghi_tx001210gb.
Threadlockers and Sealants Threadlockers and Sealants Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container.
Threadlockers and Sealants Threadlockers and Sealants (continued) Threadlocking adhesives and sealants are specified throughout this manual by a notation of “S” plus a number (S#) and should be used where indicated. Threadlocking compounds normally break down at temperatures above 175°C (350°F). If a screw or bolt is hard to remove, heat it using a small propane torch to break down the sealant. When applying sealants, follow instructions on container.
Torque Values Torque Values Metric Fasteners (DIN) TORQUE VALUES (Based on Bolt Size and Hardness) 8.8 10.9 WRENCH SIZE 12.9 Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch M3 1.2 *11 1.6 *14 2.1 *19 5.5 7/32 2.5 – M4 2.9 *26 4.1 *36 4.9 *43 7 9/32 3 – M5 6.0 *53 8.
Torque Values Torque Values (continued) Inch Fasteners (SAE) Size Nm ft.lb. Nm ft.lb. Nm ft.lb. Metric Inch Metric Inch No.4 0.7 *6 1.0 *14 1.4 *12 5.5 1/4 – 3/32 No.6 1.4 *12 1.9 *17 2.4 *21 8 5/16 – 7/64 No.8 2.5 *22 3.5 *31 4.7 *42 9 11/32 – 9/64 No.10 3.6 *32 5.1 *45 6.8 *60 – 3/8 – 5/32 1/4 8.
Ground Heaters, Inc.
