Wacker Neuson CUB400 User manual

Operator’s Manual

Indirect-Fired Air Heaters

Cub 400

Cub 700

0170815en 005 1109

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 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: (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.

Foreword

ghi_tx001366gb.fm 3

Foreword

Machines

covered by

this manual

This manual covers machines with the following item numbers:

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 main-

tain 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.

Copyright

notice

 All rights, especially copying and distribution rights, are reserved.

 This publication may be reproduced through photocopying by the original pur-

chaser 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 Cor-

poration represents an infringement of valid copyrights, and violators will be

prosecuted.

Trademarks

All trademarks referenced in this manual are the property of their respective own-

ers.

Machine Item Number Revison

Cub 400 0620206 199 and below

Cub 400 0620211 199 and below

Cub 400 0620212 199 and below

Machine Item Number Revison

Cub 700 0620208 199 and below

Cub 700 0620213 199 and below

Cub 700 0620207 199 and below

Foreword

4 ghi_tx001366gb.fm

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.

CALIFORNIA

Proposition

65 Warning:

Diesel 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.

Cub 400/700 Table of Contents

wcghi_bo0170815en_005TOC.fm 5

Foreword 3

1 Safety Information 7

1.1 Signal Words Found in this Manual ...................................................... 7

1.2 Operating Safety .................................................................................. 8

1.3 Operator Safety while using Combustion Burners ............................... 9

1.4 Service Safety .................................................................................... 10

1.5 Label Locations .................................................................................. 11

1.6 Safety and Operating Labels .............................................................. 12

2 Operation 13

2.1 System Description ............................................................................ 13

2.2 Installing the Lift Bar ........................................................................... 14

2.3 Machine Location ............................................................................... 15

2.4 System Component Locations ........................................................... 16

2.5 Control Panel ...................................................................................... 17

2.6 Preliminary Checks ............................................................................ 18

2.7 Starting the Machine .......................................................................... 18

2.8 Preheating the Fuel Filter ................................................................... 19

2.9 Shutting Down the Machine ............................................................... 20

2.10 Using the Remote Thermostat ........................................................... 21

2.11 Suggested Venting ............................................................................. 22

2.12 Adjusting the Recirculation System .................................................... 24

2.13 Connecting the Main Electric Power Supply ...................................... 25

2.14 Installing the Plenums ........................................................................ 26

2.15 Checking the Burner Air Setting ......................................................... 27

3 Maintenance 29

3.1 Periodic Maintenance Schedule ......................................................... 29

3.2 Changing and Adjusting the Supply Blower Belt ................................ 30

3.3 Replacing the Oil Burner Nozzle ........................................................ 32

3.4 Changing the Fuel Heater Filter ......................................................... 34

3.5 Checking and Adjusting the Electrode and Ionization Probe ............. 36

3.6 Checking Function of Ionization Probe ............................................... 37

3.7 Maintaining the Heater Weldment ...................................................... 38

Table of Contents Cub 400/700

6 wcghi_bo0170815en_005TOC.fm

3.8 Transporting ........................................................................................40

3.9 List of Abbreviations ............................................................................41

3.10 Troubleshooting ...................................................................................42

4 Schematics 44

4.1 Cub 400—Oil Burning .........................................................................44

4.2 Cub 400 Components—Oil Burning ....................................................45

4.3 Cub 700—Oil Burning .........................................................................46

4.4 Cub 700 Components—Oil Burning ....................................................47

4.5 Cub 400—Gas Burning .......................................................................48

4.6 Cub 400 Components—Gas Burning ..................................................49

4.7 Cub 700—Gas Burning .......................................................................50

4.8 Cub 700 Components—Gas Burning ..................................................51

5 Technical Data 52

5.1 Cub 400 Technical Data ......................................................................52

Cub 400/700 Safety Information

wcghi_si000198gb.fm 7

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.

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 mes-

sages 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.

Safety Information Cub 400/700

8 wcghi_si000198gb.fm

1.2 Operating Safety

Familiarity and proper training are required for the safe operation of

this machine. Machines operated improperly or by untrained personnel

can be dangerous. Read the operating instructions contained in both

this manual and the OEM manuals included with this machine.

Familiarize yourself with the location and proper use of all controls.

Inexperienced operators should receive instruction from someone

familiar with the machine before being allowed to operate it.

NEVER run the machine indoors or in an enclosed area unless

adequate ventilation, through such items as exhaust fans or hoses, is

provided. Exhaust gas from the genset and from the burner contains

carbon monoxide, a deadly poison. Exposure to carbon monoxide

WILL KILL YOU IN MINUTES.

Always use caution when applying power to the machine. Upon

applying power to the machine, the blower may start without warning.

1.2.1 Be sure the machine is on a firm, level surface and will not tip, roll,

slide, or fall while operating.

1.2.2 NEVER start a machine in need of repair.

1.2.3 Keep unauthorized personnel, children, and pets away from the

machine.

1.2.4 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.

1.2.5 Do not smoke while operating the machine.

1.2.6 NEVER run the machine in areas that contain flammable objects,

fuels, or products that produce flammable vapors.

1.2.7 NEVER connect ductwork between the exhaust outlet port and the

supply air inlet port.

WARNING

CAUTION

Cub 400/700 Safety Information

wcghi_si000198gb.fm 9

1.3 Operator Safety while using Combustion Burners

Combustion burners present special hazards during operation and

fueling. Read and follow the warning instructions in the burner owner’s

manual and the safety guidelines below. Failure to follow the warnings

and safety guidelines could result in severe injury or death.

NEVER run the machine indoors or in an enclosed area unless

adequate ventilation, through such items as exhaust fans or hoses, is

provided. Exhaust gas from the genset and from the burner contains

carbon monoxide, a deadly poison. Exposure to carbon monoxide

WILL KILL YOU IN MINUTES.

1.3.1 Do not fill or drain the fuel tank near an open flame, while smoking, or

while the engine is running.

1.3.2 Refill the fuel tank in a well-ventilated area.

1.3.3 Replace the fuel tank cap after refueling.

1.3.4 DO NOT spill fuel when refueling the machine. Clean up spilled fuel

immediately.

1.3.5 DO NOT smoke when refueling machine.

1.3.6 DO NOT refuel a hot or running machine.

1.3.7 The machine must be installed by qualified personnel who have read

and understand all supplied manuals and instructions.

1.3.8 All connections to natural gas or LP must be performed by qualified

personnel who possess the proper certification or lincensing required

by the locality, state, or province in which the machine is being

installed.

WARNING

Safety Information Cub 400/700

10 wcghi_si000198gb.fm

1.4 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.

1.4.1 All connections to natural gas or LP must be performed by qualified

personnel who possess the proper certification or lincensing required

by the locality, state, or province in which the machine is being

installed.

1.4.2 ALWAYS replace the safety devices and guards after repairs and

maintenance.

1.4.3 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.

1.4.4 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.

1.4.5 ALWAYS replace or repair electrical components with components

that are identical in rating and performance as the original component.

1.4.6 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.

WARNING

Cub 400/700 Safety Information

wcghi_si000198gb.fm 11

1.5 Label Locations

4

7

3

1

2

6

wcghi_gr004415

4

5

8

Safety Information Cub 400/700

12 wcghi_si000198gb.fm

1.6 Safety and Operating Labels

* Not used on NG and LP machines.

Ref. Label Ref Label

12

34

5* 6

7

Cub 400/700 Operation

wcghi_tx000683gb.fm 13

2 Operation

2.1 System Description

The Cub 400 and Cub 700 heaters are indirect-fired air heaters. The

Cub 400 and 700 have stainless steel fireboxes and heat exchangers.

They run on three fuel options: diesel, natural gas (NG), or LP. The fuel

is consumed in a closed combustion chamber. The exhaust gases are

vented outdoors through a vent pipe. The clean, dry hot air is blown or

ciculated in the space by a centrifugal blower. The blower assembly is

protected by a guard fitted on the air inlet.

Cub 400 and Cub 700 heaters are meant to heat air on construction

sites and in other rugged applications. Do not use the Cub 400 or Cub

700 for any other purpose.

Operation Cub 400/700

14 wcghi_tx000683gb.fm

2.2 Installing the Lift Bar

See graphic: wcghi_gr004433

The Cub 700 diesel with tank machine (item #: 0620213) is shipped

with the lift bar partially assembled. Before use, the lift bar must be

removed from its mounting location and installed on top of the

machine. To install the lift bar, carry out the following procedure:

2.2.1 Unpack the machine.

2.2.2 Remove and discard the bolts (a) that secure the lift bar to the side of

the machine.

2.2.3 Install the lift bar on top of the machine using the supplied 16 bolts (b).

Note: The bolts (b) are 3/8 inch 16X1.5 inches and are supplied in a

small plastic bag attached to the lift bar at the time of shipment.

2.2.4 Install the supplied bolts (c) on the support frame.

Note: The bolts (c) are 3/8 inch 16X1 inch and are supplied in a small

plastic bag attached to the lift bar at the time of shipment.

2.2.5 The lift bar is now installed.

a

c

b

wcghi

_

gr004433

Cub 400/700 Operation

wcghi_tx000683gb.fm 15

2.3 Machine Location

The machine may be located outdoors or within the area to be heated.

When locating the machine within the area to be heated, the exhaust

gases must be vented to the outdoors.

The machine must be installed:

• By qualified personnel who have read and understood all sup-

plied instructions.

• On a flat, firm surface.

• With the following minimum clearances:

• 10 ft. (3.1 m) to front

• 6 ft. (2 m) to rear

• 4 ft. (1.1m) to sides

• 4 ft. (1.1 m) to top

Operation Cub 400/700

16 wcghi_tx000683gb.fm

2.4 System Component Locations

Ref. Description Ref. Description

1 Control panel 7 Heated fuel filter

2 Burner assembly 8 Fork lift pockets

3 Recirculation damper 9 Blower temperature capillary tube

4 Heater temperature capillary tube 10 Over-temperature capillary tube

5 Supply air port 11 Fuel tank

6 Lifting eye (if equipped) 12 Burner exhaust port

wcghi_gr003885

1

3

5

8

5

3

12

3

1

2

11

7

6

10

4

9

2

7

Cub 400/700 Operation

wcghi_tx000683gb.fm 17

2.5 Control Panel

Ref Component Function

a Operation mode

switch

3-position switch which switches power to one of three modes:

• VENTILATE—power to blower only.

• OFF—power to burner is off; power remains to blower until thermo-

stat reads 104°F (40°C) or lower.

• HEAT—power to burner and blower. The blower starts immediately

when the switch is in this position.

b Reset switch Resets the system after an over-temperature condition. An over-tem-

perature condition exists at temperatures above 212°F (100°C).

Remove cap to access reset button.

a

b

wcghi_gr003880

Operation Cub 400/700

18 wcghi_tx000683gb.fm

2.6 Preliminary Checks

Before starting the Cub 400 or Cub 700, check the following:

• Fuel supply on diesel burning machines. See Fuel Blending

Guide.

• Position of operation mode switch. It must be in the OFF (“0”)

position.

• Power supply.Each machine must be connected to two (2) sepa-

rate power supplies adhering to specific requirements. Please

see the Technical Data tables in this manual for the specific

power requirements.

Note: On diesel burning machines, the fuel heater will begin

heating the fuel as soon as power is connected to the machine.

• Thermostat plug/remote thermostat connection. Either the ther-

mostat plug or the remote thermostat cable must be connected in

order for the machine to operate.

2.7 Starting the Machine

2.7.1 If using the remote thermostat, place it in the area to be heated. Set it

to the desired temperature.

2.7.2 Turn the operation mode switch to

the HEAT position.

The blower will start immediately.

The burner will start. It will go through

a prepurge cycle and then light.

The burner will continue to fire until

the temperature of the space being

heated reaches the temperature set by the thermostat. At that time, the

burner shuts down but the blower will remain on.

Cub 400/700 Operation

wcghi_tx000683gb.fm 19

2.8 Preheating the Fuel Filter

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 low-

wattage 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.

• Wear safety gloves when handling the fuel filter.

Note: Excess heating may increase the need for maintenance. See

sections “Replacing the Fuel Filter” and “Replacing the Burner Nozzle”.

To preheat the fuel, carry out the following procedure.

2.8.1 Connect power to the machine. See section Connecting Power to the

Machine.

2.8.2 Wait 20-30 minutes—longer for colder temperatures.

2.8.3 Start the machine. See section Starting the Machine.

Note: In extreme wind, the machine may need to be temporarily

blocked from the wind in order to start.

2.8.4 If the burner does not start on the first attempt, allow the power-on

sequence to cycle again (see 3.10.3).

2.8.5 If, after the second power-on sequence completes, the machine will

not fire, move the power switch to the off position.

2.8.6 Wait another 20-30 minutes and attempt to start the machine again.

CAUTION

Operation Cub 400/700

20 wcghi_tx000683gb.fm

2.9 Shutting Down the Machine

2.9.1 Turn the operation mode switch to

the OFF (“0”) position.

The burner will shut down.

As soon as the air temperature

decreases to below approximately

104°F (40°C), the blower will stop.

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.

2.9.2 Once the blower has shut off automatically, disconnect the power

supply cord.

NOTICE: Do not disconnect the power supply cord until the blower has

cooled the heat exchanger and has shut off automatically.

2.9.3 Disconnect the remote thermostat and re-install the thermostat plug.

2.9.4 When using NG or LP gas, have a qualified and licensed technician

disconnect the gas supply.

WARNING

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