Wacker Neuson Cub 200 Operating instructions

Repair Manual
Indirect-Fired Air Heater
Cub 200
Cub 300
0179422en 001 1009
0179422EN

Copyright
notice
© Copyright 2009 by Wacker Neuson Corporation.
All rights, including copying and distribution rights, are reserved.
This publication may be photocopied by the original purchaser of the machine. Any
other type of reproduction is prohibited without express written permission from
Wacker Neuson Corporation.
Any type of reproduction or distribution not authorized by Wacker Neuson Corporation
represents an infringement of valid copyrights. Violators will be prosecuted.
Trademarks All trademarks referenced in this manual are the property of their respective owners.
Manufacturer Wacker Neuson Corporation
N92W15000 Anthony Avenue
Menomonee Falls, WI 53051 U.S.A.
Tel: [phone] · Fax: [phone] · Tel: [phone]
www.wackerneuson.com

Cub 200/300 Foreword
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Foreword
Machines
covered by
this manual
Machine
documentation
Keep a copy of the Operator’s Manual with the machine at all times.
Use the separate Parts Book supplied with the machine to order replacement
parts.
If you are missing any of these documents, please contact Wacker Neuson
Corporation to order a replacement or visit www.wackerneuson.com.
When ordering parts or requesting service information, be prepared to provide
the machine model number, item number, revision number, and serial number.
Expectations
for
information in
this manual
This manual provides information and procedures to safely operate and
maintain the above Wacker Neuson model(s). For your own safety and to
reduce the risk of injury, carefully read, understand, and observe all instructions
described in this manual.
Wacker Neuson Corporation expressly reserves the right to make technical
modifications, even without notice, which improve the performance or safety
standards of its machines.
The information contained in this manual is based on machines manufactured
up until the time of publication. Wacker Neuson Corporation reserves the right to
change any portion of this information without notice.
Manufacturer’s
approval
This manual contains several references to approved parts, attachments, and mod-
ifications. The following definitions apply:
Approved parts or attachments are those either manufactured or provided by
Wacker Neuson.
Approved modifications are those performed by an authorized Wacker Neu-
son service center according to written instructions published by Wacker Neu-
son.
Unapproved parts, attachments, and modifications are those that do not
meet the approved criteria.
Unapproved parts, attachments, or modifications may have the following conse-
quences:
Serious injury hazards to the operator and persons in the work area
Permanent damage to the machine which will not be covered under warranty
Contact your Wacker Neuson dealer immediately if you have questions about
approved or unapproved parts, attachments, or modifications.
Machine Item Number Machine Item Number
Cub 200 0620204 Cub 300 0620233
Cub 200 0620262 — —

Foreword Cub 200/300
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Cub 200/300 Table of Contents
5
1 Safety Information 7
1.1 Signal Words Found in this Manual ...................................................... 7
1.2 Safety Guidelines for Operating the Machine ....................................... 8
1.3 Safety Guidelines for Lifting the Machine ............................................. 9
1.4 Safety Guidelines While Using Combustion Burners ......................... 10
1.5 Safety Guidelines for Maintaining the Machine .................................. 11
2 Operation 12
2.1 Controls and Components .................................................................. 12
2.2 Control Panel ...................................................................................... 13
2.3 Starting/Stopping the Machine ........................................................... 14
3 Burner Setup 16
3.1 Control Board Sequence of Operation ............................................... 16
3.2 Setting Up the Burner ......................................................................... 18
3.3 Removing and Installing the Burner Assembly ................................... 21
3.4 Checking and Adjusting the Burner Electrodes .................................. 22
3.5 Checking and Replacing the Burner Nozzle ....................................... 23
3.6 Setting the Air Band ........................................................................... 24
3.7 Checking and Adjusting the Fuel Pressure ........................................ 25
4 Troubleshooting Basics 27
5 Troubleshooting the Blower 28
5.1 Checking the Fuse ............................................................................. 29
5.2 Checking Power to/from the Control Board ........................................ 31
5.3 Checking the ON-OFF Switch ............................................................ 33
5.4 Checking the Capacitor ...................................................................... 35

Table of Contents Cub 200/300
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6 Troubleshooting the Burner 37
6.1 Checking the Ignition Transformer ......................................................39
6.2 Checking the Cad Cell .........................................................................42
6.3 Checking the Fuel Filter Heater ...........................................................44
6.4 Checking Output Voltage from the Control Board ...............................46
6.5 Checking the Air Pressure Switch .......................................................48
6.6 Checking the Fuel Solenoid ................................................................51
6.7 Checking the Flame Head ...................................................................54
6.8 Checking the Fuel Flow from the Nozzle .............................................55
6.9 Checking the Fuel Lines ......................................................................57
6.10 Checking the Fuel Pump Adapter .......................................................58
7 Schematic 59
7.1 Cub 200/Cub 300 Schematic ..............................................................59

Cub 200/300 Safety Information
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1 Safety Information
1.1 Signal Words Found in this Manual
NOTICE: Used without the safety alert symbol, NOTICE indicates a situation
which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
fObey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
fTo avoid death or serious injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
fTo avoid possible death or serious injury from this type of hazard, obey all safety
messages that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
fTo avoid possible minor or moderate injury from this type of hazard, obey all
safety messages that follow this signal word.

Safety Information Cub 200/300
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1.2 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. People
operating the machine must be familiar with the potential risks and hazards
associated with it.
Machine
condition
Only operate the machine when:
All safety devices and guards are in place and in working order.
All controls operate correctly.
The machine is set up correctly according to the instructions in the Operator’s
Manual.
The machine is clean.
The machine’s labels are legible.
When operating the machine:
Do not modify or defeat the safety devices.
Do not use worn electrical cords.
Do not use faulty fuel supplies.
Guidelines for
operator
When operating the machine:
Remain aware of the machine’s moving parts. Keep hands, feet, and loose
clothing away from the machine’s moving parts.
Wear protective clothing appropriate to the job site when operating the machine.
Wear safety glasses.
When operating the machine:
Do not operate a machine in need of repair.
Do not smoke near the machine.
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.

Cub 200/300 Safety Information
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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.
1.3 Safety Guidelines for Lifting the Machine
Lifting/
transporting
the machine
When lifting/transporting the machine:
Make sure all lifting devices are attached securely and have enough weight-
bearing capacity to lift or hold the machine safely.
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.
Only use suitable transport vehicles with sufficient load-carrying capacity.
When lifting the machine:
Never walk or stand under a suspended machine.
Never climb, sit, or stand on the machine while lifting it or transporting it.

Safety Information Cub 200/300
10 ghi_si000343gb.fm
1.4 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:
Do not fill or drain the fuel tank near an open flame or while the machine is
running.
Do not smoke when refueling the machine.
DANGER
Exhaust gas from the burner contains carbon monoxide, a deadly poison. Exposure
to carbon monoxide can kill you in minutes.
fNever run the machine indoors or in an enclosed area unless the machine is
vented properly.