Wacker Neuson Cub 300 HD User manual

Indirect-fired Air
Heaters
Cub 200/300/300 HD
OPERATOR’S MANUAL
0170893en 006
0809
0170893EN

Foreword
wcghi_tx000001gb diesel.fm 3
1 Foreword
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.
Keep this manual or a copy of it with the machine. If you lose this
manual or need an additional copy, please contact Wacker Neuson
Corporation. This machine is built with user safety in mind; however, it
can present hazards if improperly operated and serviced. Follow
operating instructions carefully! If you have questions about operating
or servicing this equipment, please contact Wacker Neuson
Corporation.
The information contained in this manual was based on machines in
production at the time of publication. Wacker Neuson Corporation
reserves the right to change any portion of this information without
notice.
All rights, especially copying and distribution rights, are reserved.
Copyright 2009 by Wacker Neuson Corporation.
No part of this publication may be reproduced in any form or by any
means, electronic or mechanical, including photocopying, 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
and will be prosecuted. We expressly reserve the right to make
technical modifications, even without due notice, which aim at
improving our machines or their safety standards.
WARNING

Foreword
wcghi_tx000001gb diesel.fm 4
Notes:

Table of Contents
ghi_bo0170893en_006TOC.fm 5
1. Foreword 3
2. Safety Information 7
2.1 Operating Safety .................................................................................. 7
2.2 Operator Safety while using Combustion Burners ............................... 8
2.3 Service Safety ...................................................................................... 8
2.4 Label Locations .................................................................................. 10
2.5 Label Descriptions .............................................................................. 11
3. Operation 15
3.1 System Description ............................................................................ 15
3.2 Installing the Lift Brackets .................................................................. 15
3.3 System Component Locations ........................................................... 16
3.4 Mounting the Handle and Base Assembly ......................................... 17
3.5 Machine Location ............................................................................... 18
3.6 Suggested Venting ............................................................................. 18
3.7 Connecting Power to the Machine ..................................................... 20
3.8 Preliminary Checks ............................................................................ 20
3.9 Control Panel ...................................................................................... 21
3.10 Starting the Machine .......................................................................... 22
3.11 Starting the Machine in (Extreme) Cold Weather ............................... 23
3.12 Shutting Down the Machine ............................................................... 24
3.13 Using the Remote Thermostat ........................................................... 25
4. Maintenance 27
4.1 Periodic Maintenance Schedule ......................................................... 27
4.2 Removing and Installing the Burner Assembly ................................... 28
4.3 Replacing the Burner Nozzle .............................................................. 30
4.4 Replacing the Fuel Filter .................................................................... 31
4.5 Inspecting and Aligning the Burner Electrodes .................................. 32
4.6 Inspecting and Cleaning the Cadmium (CAD) Cell ............................ 33
4.7 Checking and Adjusting the Fuel Pressure ........................................ 34
4.8 Cleaning the Fan Blades and Motor ................................................... 36
4.9 Cleaning the Interior Shell .................................................................. 37
4.10 Inspecting the Flame Head ................................................................ 38

Table of Contents
ghi_bo0170893en_006TOC.fm 6
4.11 Inspecting the Electrical Connections .................................................39
4.12 Fuel Blend Guide .................................................................................39
4.13 Transporting ........................................................................................40
4.14 List of Abbreviations ............................................................................41
4.15 Troubleshooting ...................................................................................42
4.16 Cub 200/300 Wiring Schematic ...........................................................44
4.17 Cub 300 HD Wiring Schematic ............................................................44
4.18 Schematic Legend ...............................................................................45
5. Technical Data 47
5.1 Machine Technical Data ......................................................................47

Cub 200/300/300 HD Safety Information
wcghi_si000212gb.fm 7
2 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.
DANGER indicates a hazardous situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE:Used without the safety alert symbol, NOTICE indicates a
situation which, if not avoided, could result in property damage.
Note: Contains additional information important to a procedure.
2.1 Operating Safety
Familiarity and proper training are required for the safe operation of
equipment! Equipment operated improperly or by untrained personnel
can be dangerous! Read the operating instructions contained in this
manual and familiarize yourself with the location and proper use of all
controls. Inexperienced operators should receive instruction from
someone familiar with the equipment before being allowed to operate
the machine.
2.1.1 Be sure the machine is on a firm, level surface and will not tip, roll,
slide, or fall while operating.
2.1.2 NEVER start a machine in need of repair.
DANGER
WARNING
CAUTION
WARNING

Safety Information Cub 200/300/300 HD
wcghi_si000212gb.fm 8
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.
2.1.5 NEVER run the machine indoors or in an enclosed area unless
adequate ventilation, through such items as exhaust fans or hoses, is
provided and if local and national codes permit. Exhaust from the
burner contains poisonous carbon monoxide gas. Exposure to carbon
monoxide can cause loss of consciousness and may lead to death.
2.1.6 Do not smoke while operating the machine.
2.1.7 NEVER run the machine in areas that contain flammable objects,
fuels, or products that produce flammable vapors.
2.1.8 NEVER connect ductwork between the exhaust outlet port and the
supply air inlet port.
2.1.9 NEVER block the air inlet or outlet.
2.1.10 The installation of this machine must be in accordance with the
regulations put forth by all governing bodies having jurisdiction
including the Canadian Standard B139.
2.2 Operator Safety while using Combustion Burners
2.2.1 Refill the fuel tank in a well-ventilated area.
2.2.2 Replace the fuel tank cap after refueling.
2.2.3 DO NOT spill fuel when refueling the machine. Clean up spilled fuel
immediately.
2.2.4 DO NOT smoke when refueling machine.
2.2.5 DO NOT refuel a hot or running machine.
2.2.6 The machine must be installed by qualified personnel who have read
and understand all supplied manuals and instructions.
2.2.7 When operating the machine indoors, install a carbon monoxide
detector in the work area according to the detector manufacturer’s
instructions.
2.2.8
2.3 Service Safety
HIGH VOLTAGE! This unit uses high voltage circuits capable of
causing serious injury or death. Only a qualified electrician should
troubleshoot or repair electrical problems occurring with this
equipment.
WARNING

Cub 200/300/300 HD Safety Information
wcghi_si000212gb.fm 9
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 weight-
bearing capacity to lift or hold the machine safely. Always remain
aware of the location of other people in the area when lifting the
machine.
2.3.4 ALWAYS replace or repair electrical components with components
that are identical in rating and performance as the original component.
2.3.5 Do not use gasoline or other types of fuels or flammable solvents to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
2.3.6 Always wear protective epuipment when servicing the machine. Some
machine components may be hot and contain hot fluids.
2.3.7 Notes:

Safety Information Cub 200/300/300 HD
wcghi_si000212gb.fm 10
2.4 Label Locations

Cub 200/300/300 HD Safety Information
wcghi_si000212gb.fm 11
2.5 Label Descriptions
Ref. Label Label Text
1Danger! Hazardous voltage. Do not oper-
ate without this cover in place. Disconnect
and lock out power source before opening
panel. Could cause severe injury or death.
2Warning: Blower can automatically start
which can cause serious injury. Disconnect
power source before servicing.
3Warning: Blower can automatically start
which can cause serious injury. Disconnect
power source before servicing.
WARNING
WARNUNG
ADVERTENCIA
AVERTISSEMENT
177370

Safety Information Cub 200/300/300 HD
wcghi_si000212gb.fm 12
4Using a heater indoors can kill you in min-
utes. Heater exhaust contains carbon mon-
oxide. This is a poison you cannot see or
smell. During indoor operation, vent
exhaust gas outdoors. Refer to Operator's
Manual.
5Warning: Electric shock hazard.
Disconnect power before servicing.
Read Operator’s Manual.
6Danger: To avoid injury from moving parts,
shut off the equipment before removing this
cover.
7Caution: This machine uses diesel fuel.
8Hot surface hazard!
9Caution: Lift point.
Attach lifting device in this location.
Ref. Label Label Text
DANGER
TO AVOID INJURY FROM
MOVING PARTS, SHUT OFF
THE EQUIPMENT BEFORE
REMOVING THIS COVER.
D
DIESEL
CAUTION
VORSICHT
PRECAUCION
PRECAUCION




CAUTION
VORSICHT
PRECAUCION
PRECAUTION

Cub 200/300/300 HD Safety Information
wcghi_si000212gb.fm 13
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.
14 Model and serial number label: This label
shows the model name and the serial num-
ber for the heat exchanger on your
machine.
Ref. Label Label Text

Safety Information Cub 200/300/300 HD
wcghi_si000212gb.fm 14
15 A nameplate listing the model number, item
number, revision number, and serial num-
ber is attached to each unit. Please record
the information found on this plate so it will
be available should the nameplate become
lost or damaged. When ordering parts or
requesting service information, you will
always be asked to specify the model num-
ber, item number, revision number, and
serial number of the unit.
16 Schematic label. This label, located behind
the control panel, shows the electrical
schematic for the machine.
17 Installation and instruction label. This label
shows installation and operation instruc-
tions for the unit.
18 Center of gravity.
Ref. Label Label Text

Cub 200/300/300 HD Operation
wcghi_tx000720gb.fm 15
3 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. The clean, dry hot air is recirculated by
means of an enclosed blower.
The Cub series Air Heater machines are intended to heat air on
construction sites and in other rugged environments. Do not use the
machines for any other purpose.
3.2 Installing the Lift Brackets
See graphic ghi_gr005931
Before attempting to lift the Cub 200 and 300 models, the lift brackets
must be installed.
3.2.1 Remove the machine from the crate.
3.2.2 Intstall the four lift brackets (a) as shown using the supplied bolts and
washers.

Operation Cub 200/300/300 HD
wcghi_tx000720gb.fm 16
3.3 System Component Locations
Ref Component Ref Component
1 Fuel tank 2 Air outlet
3 Flue collar (vent) 4 Burner access panel
5 Handle (and base) 6 Control panel
7 Blower 8 Fuel oil filter
9 Lifting device 10 Duct adapter

Cub 200/300/300 HD Operation
wcghi_tx000720gb.fm 17
3.4 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.
Note: The Cub 300 HD requires that only the handle be attached.
Refer to the procedure below to install the handle.
3.4.1 Attach the axles to the sides of the fuel tank using the supplied bolts
and washers.
3.4.2 Install the wheels using a rubber mallet to secure them to the axle
ends.
3.4.3 Attach the base support to the rear of the fuel tank using the supplied
bolts and washers.
3.4.4 Attach the handle to the machine using the supplied bolts (and
washers, if applicable).

Operation Cub 200/300/300 HD
wcghi_tx000720gb.fm 18
3.5 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.) to sides.
• 1.52 m (5 ft.) to top.
• 0.915 m (3 ft.) to flue pipe.
3.6 Suggested Venting
See Graphic: wcghi_gr003990
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.
When installing vents:
• Adhere to all local and national codes.
• Consult all appropriate governing bodies or local contractor for
venting and fresh air requirements.
• Place the machine in a manner that avoids excessive vent bends
(elbows), and long horizontal runs.
• Keep air inlets and outlets free from obstruction.
• Route the venting pipes in a manner that avoids any flammable
material.
• Route the venting pipes in a manner that avoids contact with
humans.
WARNING

Cub 200/300/300 HD Operation
wcghi_tx000720gb.fm 19
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.
• The above venting diagram shows suggested venting layouts
only. Consult all appropriate governing bodies or local contractor
for venting and fresh air requirements.
WARNING

Operation Cub 200/300/300 HD
wcghi_tx000720gb.fm 20
3.7 Connecting Power to the Machine
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:
• Fuel supply on diesel burning machines. See Fuel Blend Guide.
• Position of power switch. It must be in the Off (“O”) position.
• Power supply. The machine must be connected to a 115V 60Hz
power supply.
• Machine location. Ensure that the machine is properly located
according to the Machine Location guidelines in this manual.
• Remote thermostat connection. If the remote thermostat will not
be used, the remote thermostat receptacle cover must be
installed.
WARNING