AEG-Electrolux 2500HG, 4000HG User Manual
GENERAL INDEX
GB
D
NL
F
SP
................................................ Pag. 1÷9
................................................ Pag. 10÷18
I
................................................ Pag. 19÷27
................................................ Pag. 28÷36
................................................ Pag. 37÷45
................................................ Pag. 46÷54
FORLI' Italy
INDEX
Description Page
1.0 Identification .................................................. 2
1.1 Manufacturer ..................................................... 2
1.2 Definitions .......................................................... 2
1.3 Transport - Handling - storage ........................... 2
1.3.1 Storage conditions ............................................. 2
1.3.2 Weight ............................................................... 2
1.3.3 Overall dimensions ............................................. 2
1.3.4 Handling ............................................................ 2
2.0 Installation...................................................... 2
2.1 Authorised personnel ......................................... 2
2.2 Mounting the generator...................................... 3
2.3 Electrical connections ........................................ 3
2.3.1 Connection of the battery recharger ................... 3
2.3.2 Connection of the starter battery ........................ 3
2.3.3 Connection of the remote control panel ............. 3
2.4 Installing the fuel tank ......................................... 3
Connection to gas canister ................................ 3
3.0 General operation ......................................... 4
3.1 Description of generator and functioning ............ 4
3.2 Safety advice ..................................................... 4
3.3 Noise levels........................................................ 4
4.0 Instructions for use ...................................... 5
4.1 Starting the generator ........................................ 5
4.2 Stopping the generator ...................................... 5
4.3 Inherent risks ..................................................... 5
4.4 Improper use ..................................................... 5
4.5 Useful advices.................................................... 5
4.6 Troubleshooting ................................................. 5
5.0 Maintenance operations .............................. 6
5.1 Nature and frequency of checks ........................ 6
5.2 Maintenance operations which do not
require qualified technicians ............................... 6
5.3 Maintenance operations which require
qualified technicians ........................................... 6
5.3.1 Oil change ......................................................... 7
5.3.2 Air filter maintenance.......................................... 7
5.3.3 Spark plug maintenance .................................... 7
5.3.4 Regulating the voltage........................................ 8
6.0 Inactivity and dismantling ........................... 8
6.1 Dismantling ........................................................ 8
7.0 Dealing with fire hazards............................. 8
8.0 Technical data sheet .................................... 9
8.1 Technical specifications ..................................... 9
8.2 Wiring diagrams .........................................55÷71
© WTA srl -1998
All rights reserved
Printed in Italy
Text and graphics by: VEGA - Forlì
No part of this publication may be reproduced, copied or transmitted in any form or by any means without prior written permission from WTA
srl.
Figures, descriptions, reference and technical data in this manual are given as mere example and are not binding.
Because of WTA policy of continual product and safety improvement, we reserve the right to make changes at any time without notice.
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1.0 IDENTIFICATION
The identification plate of the machine is affixed outside
the plate casing (see fig. 1).
1.1 MANUFACTURER
WTA srl
Via Virgilio, 3
47100 FORLI' - ITALY
P. IVA 00718330400
1.2 DEFINITIONS
In this handbook, three types of “safety graphics” are used
to point out different levels of danger or any other important
information:
DANGER
Draws attention to potentially dangerous situations which
may cause serious personal injury.
CAUTION
Draws attention to potentially dangerous situations which
may cause personal injury or material damage.
1.3.3 OVERALL DIMENSIONS
See figg. 2, 3, 4 :
Model
1000 2500 3000 4000 5500
A mm 470 530 570 660 700
B mm 535 605 650 740 -C mm 565 640 680 770 -D mm 320 385 385 475 515
E mm 315 290 290 355 510
F mm 260 295 295 310 -Gmm27303062 -H mm -- 360 360 -- --
I mm 65 87 113 78 -Lmm659697265 -M mm 225 222 230 130 -Nmm36282517 -O mm 535 605 650 740 735
Pmm2730306255
TYPE "B" INSTALLATION TYPE "A" INSTALLATION
Q mm 260 295 295 310 370
X mm 590 650 690 780 770
IMPORTANT
Draws attention to situations which may cause
malfunctioning or damage to the machine.
1.3 TRANSPORT - HANDLING - STORAGE
1.3.1 STORAGE CONDITIONS
The generator is protected against sudden impact by
suitable packing consisting of cardboard, polystyrene and
a wooden frame support.
The generator should be stored horizontally in a dry and
well-ventilated room.
1.3.2 WEIGHT
Gross weight (including packing):
Mod. 1000 .......................................... Kg 50
Mod. 2500 .......................................... Kg 62
Mod. 3000 .......................................... Kg 71
Mod. 4000 .......................................... Kg 114
Mod. 5500 .......................................... Kg 140
Y mm 385 430 435 540 505
Z mm 335 305 305 380 550
OPENING DIM.
Air intake area
2
cm
220 220 220 260
1.3.4 HANDLING
The packed generator can be handled by normal means of
lifting and transport.
Boxes are fitted with spacers which enable the use of
manual fork-lifts.
DANGER
Strictly observe the accident prevention precautions and
safety regulations during lifting and transport, and always
use machines
be lifted.
2.0 INSTALLATION
2.1 AUTHORISED PERSONNEL
The generator shall be installed onto the vehicle (caravan,
motorhome or special vehicle) by authorised personnel
only, namely by skilled technicians or workshops, authorised
directly by W.T.A.
If the installation is carried out by non-authorized technicians
with a higher maximum capacity than the load to
2
or workshops, W.T.A. disclaims any responsibility for the
safety and efficient running of the generator according to
the M.D. 89/392/EEC.
DANGER
The instructions given in sections 2.2 - 2.3 - 2.4 are
addressed to qualified technicians only.
2.2 MOUNTING THE GENERATOR
Generators mod. 1000 - 2500 - 3000 - 4000 are provided
with fixing brackets,vibration dampers and petrol filter to be
placed on the fuel feed hose to the generator. Brackets
allow either suspended type "A” mounting (see fig. 3) or
traditional type "B” mounting (see fig. 4).
This is made possible by the supporting frame of the outer
casing.
Generator mod. 5500 is provided with brackets for fixing
the external seal, brackets for anchoring the unit, vibration
dampers, silencer (pos. 29 fig. 16) to be coupled to the
exhaust hose delivered as accessory AG 125 (pos. 34 fig.
16), and fuel filter which is standard installed inside the
casing (pos. 33 fig. 15). The brackets (pos. 31 fig. 16) which
allow to fix the seal (pos. 35 fig. 16) allow to mount the
generator complete with seal inside the arranged
compartment and to perfectly seal the vehicle side. The
exhaust hose can be positioned at will as shown in fig. 16
by rotating the curve inwards to either upper position or
lower position. By removing the curve, it is also possible to
directly fit the exhaust pipe by crossing the casing on its lefthand side. The prearranged floor must tolerate both the
generator mass and the vibrations due to the motion of the
vehicle ("TYPE B” mounting).
The type “A” mounting (suspended installation) offers the
following advantages: reduced overall dimensions, quick
installation, easy access for both ordinary and extraordinary
maintenance operations.
Make sure there is enough space around the generator
casing for air to pass freely (for cooling). It is also necessary
to leave at least 20 mm distance between the casing and the
surrounding parts.
If the breathing manifold is positioned behind one of the
vehicle's wheels, make sure that the tyre is prevented from
throwing water into the casing when travelling on wet roads.
For the type “A” mounting, use the plate supports provided
to ensure that the genset is fixed securely. If type “B”
mounting is preferred (traditional installation), a watertight
compartment (fig. 2), set towards the vehicle interior and
having the dimensions given in section 1.3.3, needs to be
prearranged, with exhaust holes and air inlets drilled into the
floor and door. In addition, use an exhaust union (fig. 4),
supplied as accessory, to be fixed directly onto the generator
casing with screws or rivets. In order to prevent the exhaust
gas recycling within the compartment, place flameproof
sealing around the exhaust union.
FORLI' Italy
2.3 ELECTRICAL CONNECTIONS
For the 230V use a standard cable with cross-section
according to table 1 below. Pass it inside the casing via the
airlead (pos. 30 fig. 7 and 9) and connect to the terminals
(pos. 17/18 fig. 6 and 14). Connect the earth wire to pos. 15.
The electrical circuit should have a relay or change-over
switch (such as accessory AG102/AG113), so as to prevent
any damage to the generator when the camper is connected
to an external mains supply (precedence is automatically
given to the mains).
Mod.
Cross-section Cross-section
mm2 -230 V mm2-12 V
1000 1.5 6 10 16
2500 2.5 2.5 10 16
3000 2.5 2.5 10 16
4000 4 2.5 10 16
5500 4 2.5 16 25
Power cables
Battery recharger
6 m > 6 m
Battery connection
TAB. 1
2.3.1 CONNECTION OF BATTERY
RECHARGER
Use a wire with minimum cross-section according to table
1 above to connect the terminal (pos. 16 fig. 6 and 14) to
the positive lead of the battery to be recharged.
Insert the AG111 voltage regulator, or alternatively a switch,
to interrupt recharging when complete.
(See wiring diagrams, pages 55 ÷ 71).
2.3.2 CONNECTION OF STARTER BATTERY
For starting the generator, connect the positive terminal of
the vehicle's starter battery to pos. 12 fig. 6 and 14 using a
flame-resistant sheathed cable having a cross-section
according to table 1 above.
The earth cable should have the same cross-section and be
connected from pos. 13 to the vehicle chassis. Make sure
that a clean, rust-free contact is made (i.e. rub down surface
if painted), and protect with grease.
2.3.3 CONNECTION OF REMOTE CONTROL
PANEL
Fix the control panel in desired position inside the vehicle
and use the individually-tested AG103 extension cable to
connect it to the genset by means of the connector pos. 14
fig. 6 and 14.
2.4 INSTALLING THE FUEL TANK
Install the fuel tank as near as possible to the generator and
if possible on the same horizontal level, or up to 30cm
below. As well as reducing the length of fuel pipe as much
as possible, make sure it is not bent or squashed. Do not
put the tank near sources of heat, and make sure that water
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FORLI' Italy
cannot infiltrate.
Use LOCTITE 577 to make all connections, so as to prevent
fuel leakages.
To connect the fuel tank to the generator, use a 6x13mm
rubber-coated tube, of the same type used for the genset
and suitable for unleaded petrol. For the extension, use the
ties and filter provided. It is advisable to use fuel hose
AG118 (accessory) for the connection from tank to refuellingmouth.
IMPORTANT
Model 5500 does not need fuel tank, since it is standard
fitted inside the genset casing.
CONNECTION TO GAS CANISTER
DANGER
• The unit shall be used only and exclusively with the door
closed.
• Keep inflammable substances like petrol, paints, solvents,
etc. away from the generator.
• Do not let hot parts of the genset come into contact with
inflammable materials.
• Do not fill up with the engine running if the tank is placed
close to the generator.
• Do not touch the generator or its connections with wet
hands.
• Do not replace the fuses or thermal switches with new
ones of higher amperage.
• Any check of the electrical parts shall be made with
engine stopped and by authorised technicians only.
CAUTION
For the LPG genset, withdraw the gas from the upright
canister before the vehicle's service regulator and from the
upper part, so that gas enters the genset at high pressure
and in the gaseous state.
(Minimum recommended pressure: 0.7- 0.9 bar)
3.0 GENERAL OPERATION
IMPORTANT
The firm disclaims any responsability for damages arising
from malfunctioning of the generator.
3.1 DESCRIPTION OF GENERATOR AND
FUNCTIONING
The generator consists of an endothermic petrol engine
connected to an alternator which produces both alternate
and direct current.
The unit comes in a soundproof casing made of pressed
steel plate and insulated with special deadening materials.
Fuel comes to the combustion engine through a pump
which is standard fitted on the unit itself.
The generator is manufactured according to the safety rules
given in the Conformity Declaration.
3.3 NOISE LEVELS
The generator has been submitted to a noise emission test
at a qualified ISTEDIL lab, where all the necessary tests were
carried out and EC Certificate No.I-225/92 issued, stating
following results:
Measured according to: EC DIRECTIVE 84/536
NOISE LEVEL:
Mod. 1000 .......................................... LwA 81
Mod. 2500 .......................................... LwA 85
Mod. 3000 .......................................... LwA 85
Mod. 4000 .......................................... LwA 87
Mod. 5500 .......................................... LwA 87
3.2 SAFETY ADVICE
The unit is housed within a perfectly closed casing. Therefore,
there is no danger of accidental contacts with hot or moving
parts or wires under voltage.
The door of the unit is fitted with lock and key and should
not be left within the reach of children or non-authorised
persons.
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4.0 INSTRUCTIONS FOR USE
4.1 STARTING THE GENERATOR
Normally the vehicle's 12V battery is used to start the
genset.
First press the red button (pos. 27 fig. 5) on the control panel
into the “I” position.
To start the genset from cold, press and hold down the
green START button (pos. 25 fig. 5) together with the white
CHOKE button (pos. 26 fig. 5) for max. 5 seconds.
When starting the LPG generator from cold, press the
green button (pos. 25 fig. 5) and at the same time "blip" the
white button (pos. 26 fig. 5) for about a second at intervals
of around 3 seconds. As soon as the engine fires, release
both buttons.
If the engine does not start, wait a few seconds, then repeat
the operation.
CAUTION
Do not make prolonged or repeated (more than 5 consecutive) attempts to start the genset, as this may damage the
starter motor.
4.4 IMPROPER USE
DANGER
The generator is to be installed by qualified technicians only,
according to the manufacturer’s instructions.
The generator is to be used only and exclusively for producing
current for mobile vehicles, fitted with a standard electrical
circuit in keeping with the power supplied by the generator.
4.5 USEFUL ADVICES
To use the genset at best, we remember you that little, but
prolonged, overloads may cut off thermal switches pos. 10
and 11 shown in fig. 6 and 14.
During running-in, it is advisable that the new engine is not
subjected to loads exceeding its nominal load by 70%, at
least during the first 50 running hours.
4.6 TROUBLESHOOTING
We have listed below some problems which may occur,
along with their respective causes and possible solutions.
In the case of problems which are not listed below, please
seek advice from an authorised after-sales service centre.
To start the genset when already warmed-up, or during the
summer, when the outside temperature is high, press the
green “START” button (pos. 25 fig. 5) only.
In an emergency the genset can be started manually using
the pull-cord handle (pos. 4 fig. 8 and 15) and holding the
choke magnet (pos. 36 fig. 8 and 15) shut with one hand
if the engine is cold.
The green LED on the control panel ((pos. 23 fig. 5) indicates
that the genset is running correctly.
4.2 STOPPING THE GENERATOR
Push the red “STOP” button (pos. 27 fig. 5) on control panel
into the ”0" position. Alternatively use the safety switch on
the genset itself (pos. 7 fig. 6 and 14) for models 2500 - 3000
- 4000 - 5500.
4.3 INHERENT RISKS
DANGER
The generator is fitted with a combustion engine, and
therefore runs on highly inflammable fuelstuffs.
Exhaust gases are conveyed under the casing and, although
mixed with cooling air, they are inevitably hot.
Do not touch the parts of the casing close to the exhaust
and do not place your hands or other objects within the
duct.
1 When the green “START” button (pos. 25 fig. 5)
on the control board is pressed, the generator
does not work.
Causes and Solutions:
1.1 Check that the red switch (pos. 27 fig. 5) is in the “I”
position.
1.2 Electrical wires loose or disconnected.
(Have checked by qualified personnel).
1.3 No power supplied to starter-motor.
(Have checked by qualified personnel).
1.4 Earth wire of generator disconnected.
(Have checked by qualified personnel).
2 The starter-motor turns, but the generator does
not start.
Causes and Solutions:
2.1 No fuel: check.
2.2 No oil in engine.
Check if the red warning light (pos. 6 fig. 5) on the
control board blinks during the starting phase.
Check the oil level and top up if necessary (see
Maintenance section).
2.3 The safety switch (pos. 7 fig. 6 and 14) is in the "0"
position.
Check and press in the “I” position.
2.4 Check that the engine's spark-plug nipple is fully
inserted.
2.5 No current to the spark plug.
(Have checked by qualified personnel).
2.6 No fuel getting to the carburettor.
(Have checked by qualified personnel).
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