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Wacker Neuson Cub 200, Repair Manual

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Wacker Neuson Cub 200 Repair Manual Download Page 59

Cub 200/300

Schematic

ghi_tx001210gb.fm

59

7

Schematic

7.1

Cub 200/Cub 300 Schematic

Summary of Contents for Cub 200

Page 1: ...Repair Manual Indirect Fired Air Heater Cub 200 Cub 300 0179422en 001 1009 0 1 7 9 4 2 2 E N...

Page 2: ...ten 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 pros...

Page 3: ...fety 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 po...

Page 4: ...Foreword Cub 200 300 ghi_tx001204gb fm 4...

Page 5: ...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...

Page 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...

Page 7: ...s 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 W...

Page 8: ...s 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 fault...

Page 9: ...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...

Page 10: ...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...

Page 11: ...ining the machine Reinstall the safety devices and guards after repairs and maintenance Keep all electrical cords away from heat oil vibrating surfaces and sharp edges Inspect all electrical cords bef...

Page 12: ...b fm 12 2 Operation 2 1 Controls and Components 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 filt...

Page 13: ...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 pr...

Page 14: ...to cool If using the remote thermostat Turning ON 1 Connect the remote thermostat to the control panel at the remote thermostat receptacle a 2 Place the remote thermostat in the area to be heated Set...

Page 15: ...Cub 200 300 Operation ghi_tx001205gb fm 15 Notes...

Page 16: ...It pro duces a continuous spark across the electrodes so that any resid ual fuel is ignited and burned off The flame control unit cad cell PH checks for presence of a flame If a consistent flame is d...

Page 17: ...gnition period in an attempt to re establish the flame If the flame is not re established the aftercooling period begins Aftercooling T5 After the heater is turned OFF or after flame re establishment...

Page 18: ...adjust the burner High quality combustion analyzer Smoke spot tester Fuel pressure test gauge General hand tools Mandates Adjustments made shall be done so that the machine conforms to the require men...

Page 19: ...4 Checking and Adjusting the Burner Electrodes on page 22 3 Check the burner nozzle See Section 3 5 Checking and Replacing the Burner Nozzle on page 23 4 Set the air band See Section 3 6 Setting the...

Page 20: ...e 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 Re adjust the air band if...

Page 21: ...nd 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 Rotate the burner assembly b counterclockwise and remove it from the flame he...

Page 22: ...aightness 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 Procedure Perform the pro...

Page 23: ...embly 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 I...

Page 24: ...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...

Page 25: ...ce 3 Open the access panel a 4 Remove the threaded plug b from the pressure test port using an allen wrench Set the plug in a safe location to be re installed later 5 Install a pressure gauge with BPT...

Page 26: ...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 pre...

Page 27: ...er cord to a 120 VAC power supply 2 Turn the machine on 3 Turn the machine off If Then The blower runs the problem is with the burner system See Chapter 6 Troubleshooting the Burner The blower does no...

Page 28: ...onent 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 Check the fuse 5 1...

Page 29: ...ect the power cord from the electric power supply 4 Remove the screws that hold the control panel and pull the control panel from the machine This procedure continues on the next page Yes ____ No ____...

Page 30: ...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 no...

Page 31: ...ntrol panel and pull the control panel from the machine 2 Remove the cover b from the control panel 3 Connect the power cord to a 120 VAC power supply 4 Turn the machine on This procedure continues on...

Page 32: ...Result The power to and from the control board has now been checked If the problem has not been resolved leave the machine disassembled and continue with the next topic Otherwise reassemble the machin...

Page 33: ...nd pull the control panel from the machine 3 Remove the cover b from the control panel 4 Locate the ON OFF switch c 5 Check the wiring to the ON OFF switch Make sure it is correct black to upper termi...

Page 34: ...here 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 The ON OFF switch has now been checked If the problem h...

Page 35: ...e capacitor b and remove the capacitor from the machine 4 Discharge the capacitor by placing an insulated screwdriver across its two terminals 5 Check the capacitance of the capacitor It should measur...

Page 36: ...ecks 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 fa...

Page 37: ...problems For ignition system problems check the following components in the sequence listed This procedure continues on the next page If Then There is a puff of smoke from the exhaust stack when the...

Page 38: ...der 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 If fuel pressure is OK If fuel pressure is low Order Component See...

Page 39: ...in 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...

Page 40: ...1 Measure the voltage at terminals M17 and M16 Is 108 132 VAC measured This procedure continues on the next page WARNING Electric shock hazard High voltage exists at the control panel when the machine...

Page 41: ...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 The proced...

Page 42: ...erform 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 t...

Page 43: ...ce again Note With the cad cell covered a much higher resistance should be measured Again the amount will vary depending on the amount of light the cad cell receives Is 20 000 80 000 ohms measured Res...

Page 44: ...e 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 3 Disconnect the power cord from the power supply 4 Remove the screws a...

Page 45: ...been checked Reassemble the machine 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 injur...

Page 46: ...panel and pull the control panel from the machine 3 Remove the cover b from the control panel 4 Connect the machine to the power source 5 Turn the machine on If the machine is in a fault condition pre...

Page 47: ...uch 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 7 Turn the machine off Result The output voltage from the control...

Page 48: ...and check the air hose for binding pinching or damage 4 Connect the machine to the power source 5 Turn the machine on and wait 10 seconds then measure the voltage between the air pressure switch and...

Page 49: ...een the terminals of the air pressure switch as shown Is there continuity 9 Turn the machine on If the machine is in a fault condition press the RESET c button on the control panel This procedure cont...

Page 50: ...s there continuity 11 Turn the machine off 12 Reinstall the wires Result The air pressure switch has now been checked If the problem has not been resolved leave the machine disassembled and continue w...

Page 51: ...he fuel solenoid 1 Turn the machine off 2 Open the access panel a 3 Locate the fuel solenoid b and disconnect it This procedure continues on the next page WARNING Electric shock hazard High voltage ex...

Page 52: ...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...

Page 53: ...ss the coil of the solenoid as shown Is 600 700 ohms measured Result The fuel solenoid has now been checked If the problem has not been resolved leave the machine disassembled and continue with the ne...

Page 54: ...crews a 4 Turn the flame head b counterclockwise and pull it from the machine 5 Clean the flame head if it is dirty or full of soot 6 Replace the flame head if it is damaged Result The flame head has...

Page 55: ...of the control board by removing the wires from terminals M16 and M17 3 Remove the nozzle assembly a from the flame head 4 Remove the cad cell b 5 Place the cad cell inside the flame head and cover i...

Page 56: ...ill spray fuel for approximately 1 second Observe the spray pattern c Does the fuel spray form a consistent cone pattern Result The nozzle now been checked Reassemble the machine If the problem has no...

Page 57: ...r supply disconnected Procedure 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 li...

Page 58: ...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 t...

Page 59: ...Cub 200 300 Schematic ghi_tx001210gb fm 59 7 Schematic 7 1 Cub 200 Cub 300 Schematic...

Page 60: ...311 5 ml 17380 50 ml Loctite 271 277 Hernon 427 Omnifit 1550 220M Red High strength for all threads up to 25 mm 1 Heat parts before disassembly Temp range 54 to 149 C 65 to 300 F 29312 5 ml 26685 10 m...

Page 61: ...follow instructions on container The sealants listed are recommended for use on Wacker Neuson equipment TYPE Europe COLOR USAGE PART NO SIZE Loctite 496 Hernon 110 Omnifit Sicomet 7000 Clear Instant a...

Page 62: ...5 M4 2 9 26 4 1 36 4 9 43 7 9 32 3 M5 6 0 53 8 5 6 10 7 8 5 16 4 M6 10 7 14 10 17 13 10 5 M8 25 18 35 26 41 30 13 1 2 6 M10 49 36 69 51 83 61 17 11 16 8 M12 86 63 120 88 145 107 19 3 4 10 M14 135 99 1...

Page 63: ...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 1 6 12 9 16 12 7 16 3 32 5 16 18 13 26 19 33 24 13 1 2 1 4 3 8 31 23 45 33 58 43 9 16 5 16 7 16 50 37 71 52 94 69 16 5 8...

Page 64: ...Ground Heaters Inc 1271 Judson Road Spring Lake MI 49456 Tel 231 799 9600 Fax 231 799 9500 Tel 877 799 9600...

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