www.wackergroup.com
High-frequency generator
GH 3500
0207867en 001
2.2006
Operator's manual
DANGER
CARBON MONOXIDE
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide (CO). This is a poison you cannot see or
smell. If you can smell the generator exhaust, you are breathing CO. But even if you cannot
smell the exhaust, you could be breathing CO.
• NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed
areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or
opening windows and doors does NOT supply enough fresh air.
• ONLY use a generator outside and far away from windows, doors, and vents. These
openings can pull in generator exhaust.
Even when you use a generator correctly, CO may leak into the home. ALWAYS use a
battery-powered or battery-backup CO alarm in the home.
If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh
air RIGHT AWAY. See a doctor. You could have carbon monoxide poison.
Contents
Operator’s manual 3
1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Protective gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Operating combustion engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.7 Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Components and control elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.1 Lifting eyes and tie-down lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 Transporting the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.1 Prior to starting the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Decomissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.4 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.2 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7.3 Changing the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.4 Cleaning the air filter / replacing the air filter inserts. . . . . . . . . . . . . . . . . . . . . 24
7.5 Cleaning the fuel dirt separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.6 Checking / cleaning / replacing the spark plug . . . . . . . . . . . . . . . . . . . . . . . . . 26
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
EC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Contents
4
Foreword
Operator's manual 5
1Foreword
This operator's manual contains information and procedures for the safe operation and maintenance of your Wacker machine. In the interest of your own safety
and to prevent accidents, you should carefully read through the safety information, familiarize yourself with it and observe it at all times.
This operator's manual is not a manual for extensive maintenance and repair
work. Such work should be carried out by Wacker Service or authorized specialists.
The safety of the operator was one of the most important aspects taken into consideration when this machine was designed. Nevertheless, improper use or incorrect maintenance can pose a risk. Please operate and maintain your Wacker
machine in accordance with the instructions in this operator's manual. Your reward will be troublefree operation and a high degree of availability.
Defective components should be replaced immediately!
Please contact your Wacker representative if you have any questions concerning operation or maintenance.
All rights reserved, especially reproduction and distribution rights.
Copyright 2005 Wacker Construction Equipment AG
No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without the expressed written permission of Wacker.
Any type of reproduction, distribution or storage on data media of any type and
form not authorized by Wacker represents an infringement of copyright and will
be prosecuted.
We expressly reserve the right to make technical modifications – even without
special notice – which aim at further improving our machines or their safety
standards.
Symbols used
6
2 Symbols used
Warning symbols
This operator's manual contains safety regulations of the categories:
DANGER, WARNING, CAUTION.
They should be followed to prevent danger to life and limb or damage to equipment or improper service.
Instructions
f This symbol indicates there is something for you to do.
DANGER
This symbol indicates hazards that can result in serious injury or even death.
WARNING
This symbol indicates hazards that can result in injury or severe material damage.
CAUTION
This symbol indicates hazards that can result in material damage.
GH 3500 Safety information
Operator's manual 7
3 Safety information
3.1 General instructions
State of the art
This machine has been constructed with state-of-the-art technology according to
the recognized rules of safety. Nevertheless, when used improperly, dangers to
the life and limb of the operator or to third persons or damage to the machine or
other materials cannot be excluded.
Proper use
The machine may only be used for generating 42 V high-frequency power.
Its proper use also includes the observance of all instructions contained in this
operator's manual as well as complying with the required maintenance and service instructions.
Any other use is regarded as improper. Any damage resulting from improper use
will void the warranty and the liability on behalf of the manufacturer. The operator
assumes full responsibility.
Structural modifications
Never attempt to modify the machine without the written permission of the manufacturer. Failure to do so will endanger your safety! In addition, this will void the
warranty and the liability on behalf of the manufacturer.
Requirements for operation
The ability to operate the machine safely requires:
Proper transport, storage, setup, and assembly.
Careful operation.
Careful repair work.
Operation
Operate the machine only as intended and only when in proper working condition.
Operate the machine in a safety-conscious manner with all safety devices attached and enabled. Do not modify or disable any safety devices.
Never operate the machine in a potentially explosive environment.
Safety information GH 3500
8
Maintenance
Regular maintenance is required in order for the machine to operate properly and
reliably over time. Neglected maintenance work can make the machine dangerous to use.
Strictly observe the prescribed maintenance intervals.
Do not use the machine if it requires maintenance or repairs.
Malfunctions
If you detect a malfunction, you must shut down and secure the machine immediately.
Eliminate the malfunctions that impair safety immediately!
Replace damaged or defective components immediately!
For further information, please see the chapter Troubleshooting.
Spare parts, accessories
Use only genuine Wacker spare parts and accessories. Non-compliance will exempt the manufacturer from all liability.
Exclusion of liability
Wacker will refuse to accept liability for injuries to persons or for damage to materials in the following cases:
Structural modifications.
Improper use.
Improper handling.
Use of third-party spare parts and accessories.
Operator's manual
Always keep the operator's manual near the machine or near the worksite for
quick reference.
If you have misplaced the operator's manual or require an additional copy,
please contact your Wacker representative.
Always hand over this operator's manual to other operators or to the future owner
of the machine.
Country-specific regulations
Observe the country-specific regulations, standards and guidelines in reference
to accident prevention and environmental safety, for example those pertaining to
hazardous materials and wearing protective gear.
Supplement the operator's manual with additional company, official or other general regulations that may be in effect.
GH 3500 Safety information
Operator's manual 9
Operating controls
Always keep the operating controls of the machine dry, clean, and free of oil or
grease.
The function of operating levers or controls must not be manipulated or rendered
ineffective.
Cleaning
Always keep the machine clean and be sure to clean it each time you have finished using it.
Do not use gasoline or solvents. Danger of explosion!
Checking for signs of damage
Inspect the machine when it is switched off for any signs of damage at least once
per work shift.
Have any damage or defects eliminated immediately.
Operator qualifications
Only trained personnel are permitted to start and operate the machine. The following rules also apply:
You are at least 18 years of age.
You are physically and mentally fit.
You have received instruction on how to properly use the machine.
You are familiar with required safety devices.
You are authorized to start machines and systems in accordance with the
standards governing safety.
You have been assigned to work on the machine by your company.
Incorrect operation
Incorrect operation or misuse by untrained personnel can endanger the health
and safety of the operator and/or cause machine and material damage.
3.2 Protective gear
Work clothing
Clothing should be appropriate, i.e. should be close-fitting but not restrict your
movement.
Do not wear long hair loosely, loose clothing or jewelry including rings. These objects can easily get caught or be drawn in by moving parts.
Safety information GH 3500
10
Personal protective gear
Wear personal protective gear to avoid injuries or health hazards:
Non-skid, hard-toed shoes.
Work gloves made of durable material.
Overalls made of durable material.
Hardhat.
Ear protection.
Ear protection
This machine generates noise that exceeds the country-specific permissible
noise levels (individual rating level). This is why ear protection is required in Germany starting at 89 dB(A) in accordance with BGV B3.
3.3 Transport
Switching off the machine
Before you transport the machine, it must be switched off, and the engine must
be given sufficient time to cool down.
Emptying the tank
We recommend that the fuel tank be emptied and the carburetor run dry prior to
transporting it. Fuel could run out, e.g. if the machine is tilted.
Lifting
When lifting the machine, observe the following instructions:
Designate a skilled person to guide you for the lifting procedure.
You must be able to see or hear this person.
Use only suitable and certified hoisting gear, lifting tackle and load-bearing
equipment with sufficient lifting capacities.
Only use the attachment points described in the operator's manual.
Attach the machine securely to the hoisting gear.
Ensure that no one is nearby prior to lifting the machine.
Do not climb onto the machine.
Make sure that no one walks under or stands beneath the suspended ma-
chine.
GH 3500 Safety information
Operator's manual 11
Loading
Loading ramps must be able to bear the load and be in a stable position.
Make sure that no one can be endangered if the machine slips away or tips over
or if parts suddenly move upward or downward.
Put the operating controls and moving parts in their transport position.
Secure the machine with load-securing straps so that it cannot roll or slide away
or tip over. Only use the attachment points described in the operator's manual.
Transport vehicle
Use only suitable transport vehicles with sufficient load-carrying capacities.
Restarting
Parts, accessories or tools that have been detached for transport purposes must
be carefully re-mounted and fastened before you restart the machine.
When you restart the machine, only proceed as described in the operator's manual.
3.4 Operation
Minimum distance
Stationary power units and drives must have a distance of at least one meter
from equipment, buildings or other machines.
Do not use in the rain
Protect the machine against rain, snow or any other forms of moisture.
This could cause damage or malfunctions.
Protection against water
Only operate the machine on a dry surface.
If water accumulates under the machine, you must switch off the machine and
let it dry properly.
Protection against overload
Always make sure that the power unit is not overloaded. The total amperage of
the components connected may not exceed the output limit for the power unit.
Safety information GH 3500
12
3.5 Operating combustion engines
Do not change the engine speed
Do not change the preset engine speed.
This could cause engine damage.
Dangers during operation
Combustion engines can be dangerous, particularly during operation and when
refueling. Read and follow all warnings in the operator's manual of the engine
manufacturer and the safety measures listed below. Otherwise there is a risk of
personal injury and/or material damage!
You must not leave the engine running near spilt fuel or if a fuel odor is present.
Danger of explosion!
Remove the machine from such areas.
Remove the spilt fuel immediately!
Preventing fires
Open flames and smoking are strictly prohibited in the immediate vicinity of the
machine.
Make sure that waste, such as paper, dry leaves or grass do not accumulate
around the exhaust muffler. They can easily ignite.
Safety precautions when refueling
Please observe the following safety-relevant instructions when refueling:
Switch off the engine and allow it to cool down.
Refuel in a well-ventilated environment.
Do not refuel near open flames.
Do not smoke.
Use the correct fuel grade.
Do not mix fuel with other liquids.
Fill the tank only up to the maximum marking.
Do not spill fuel, especially onto hot parts.
Remove any spilt fuel immediately.
Lock the fuel cap securely after refueling.
Checking for signs of damage
Check the engine while turned off for leaks and cracks in the fuel line, tank and
fuel cap at least once per work shift.
Do not start the engine if there is visible damage. Have any damage or defects
eliminated immediately.
GH 3500 Safety information
Operator's manual 13
No operation in closed quarters
Do not operate the machine in closed quarters!
In partially closed rooms such as tunnels, drifts or deep trenches, ensure sufficient ventilation by, for example, providing a powerful exhaust air fan.
Danger of poisoning! Do not inhale exhaust fumes. They contain toxic carbon
monoxide that can lead to unconsciousness or death.
Caution with hot parts
Do not touch any hot parts such as the engine block or exhaust muffler during
operation or directly afterwards. These parts can become very hot and cause severe burns.
Shutting off the fuel tap
When the machine stops, shut off the fuel tap.
Cleaning the engine
Clean the engine cooling fins when the engine has cooled down.
Do not use gasoline or solvents. Danger of explosion!
3.6 Maintenance
Maintenance work
Maintenance and repair work must be carried out only to the extent described in
this operator's manual. All other procedures must be performed by Wacker Service.
For further information, please see the chapter Maintenance.
Turn off the engine
Before carrying out maintenance or repair work, turn off the engine and allow it
to cool down.
For gasoline powered engines, you must pull off the spark plug connector.
3.7 Labels
Your machine has adhesive labels containing the most important instructions
and safety information.
Make sure that all the labels are kept legible.
Replace any missing or illegible labels.
Safety information GH 3500
14
Labels Description
Warning
Hot surface.
Guaranteed sound power level in dB(A).
Read the operator's manual carefully.
Danger
- Carbon dioxide emission.
- Read the operator's manual!
- Unshielded flames are strictly prohib ited.
- Switch off the engine before refueling.
Electrical waste label
Do not dispose of the machine in residual
waste.
GH 3500 Functional description
Operator's manual 15
4 Functional description
4.1 Components and control elements
4.2 Functionality
The generator generates 3-phase 42 V/200 Hz protective voltage for driving vibrators.
Note: Use either 32 A or 63 A plug receptacles.
A sudden power drop can be the result.
Item Designation Item Designation
1 Air filter 8 Oil drain plug
2 Exhaust 9 Engine switch
3 Fuel cap 10 Fuel filter
4 Main switch 11 Starter rope
5 Plug receptacles 12 Fuel tap
6 Generator 13 Choke
7 Oil level dipstick 14 Throttle lever
13 4
12
11
14
13
69
2 5
78
10
Transport GH 3500
16
5 Transport
5.1 Lifting eyes and tie-down lugs
WARNING
Read and follow all the safety instructions at the beginning of this operator's
manual, see chapter Safety information.
Improper use can result in injury or serious material damage.
Item Description
1 Lifting eyes
2 Tie-down lugs
1
2
2
GH 3500 Transport
Operator's manual 17
5.2 Transporting the machine
f Turn off the engine and allow it to cool down.
f Close the fuel tap.
Note: We recommend that the fuel tank be emptied and the carburetor run
dry prior to transporting it. Fuel could run out, e.g. if the machine is tilted.
f Use suitable lifting tackle at the lifting eyes.
f Lift the machine evenly at the lifting eyes.
f Carefully set the machine down on a suitable transport vehicle.
f Use at least two tie-down lugs to fasten the machine.
DANGER
Danger of fire and explosions by fuel!
Any fuel that escapes can ignite and cause severe burns.
Lift and move the machine in the upright position.
WARNING
Danger due to the machine falling!
If the machine falls, it can cause severe injury such as crushing.
Only use suitable and tested hoisting gear and lifting tackle of sufficient lifting
capacity.
Attach the machine firmly to the hoisting gear.
Operation GH 3500
18
6 Operation
6.1 Prior to starting the machine
Before you start the engine, check the following:
f Fuel level – the tank should be at least half full.
f Motor oil level – see 7.2 Checking engine oil level (page 22).
f Air filter – see 7.5 Cleaning the fuel dirt separator (page 25).
f Fuel lines for leaks.
f External screw connections for tightness.
6.2 Starting up
If machines are connected to the generator, they must be disconnected before
you start the engine.
Disconnecting machines
f Turn off the main switch.
f Switch off all connected machines.
f Disconnect all connected machines from the power unit.
WARNING
Read and follow all the safety instructions at the beginning of this operator's
manual, see chapter Safety information.
Improper use can result in injury or serious material damage.
GH 3500 Operation
Operator's manual 19
Starting the engine
f Open the fuel tap (a1).
f Cold start: Close the choke (d2).
Warm start: Open the choke (d1).
Note: The engine is hand warm or hotter with warm start.
f Set the engine switch to "ON" (b2).
f Push the throttle lever to the left (c2).
f Pull out the starter rope (e) until compression resistance can be felt and then
let it roll back in again.
f Pull the starter rope with force, but not suddenly.
The engine starts.
f Let starter rope slowly roll back in.
f Open the choke while the engine is warming up.
f Open the throttle lever completely for operation (c1).
Note: Pay attention to any abnormal engine noises or uneven running.
Operation GH 3500
20
Connecting machines
Note: Do not use the main switch to switch on the machines.
This could result in abrupt engine overload.
f Turn off all machine switches.
f Connect machines.
f Turn on the main switch.
f Turn on the machine switches separately.
Never turn on more than one machine switch at a time.
6.3 Decomissioning
Disconnecting machines
f Turn off the main switch.
f Switch off all connected machines.
f Disconnect all connected machines from the power unit.
Turn off the engine
f Push the throttle lever to the right to idle operation (c3).
f Set the engine switch to "OFF" (b1).
f Close the fuel tap (a2).
6.4 Cleaning
Cleaning the machine after use
f Remove any dirt of dust from the connections.
f Remove any concrete, dirt of dust from the machine.
CAUTION
Danger by water!
Water could penetrate the generator and cause an electric shock.
Do not use water to clean the machine!
GH 3500 Maintenance
Operator's manual 21
7 Maintenance
7.1 Maintenance schedule
Have worn or damaged components replaced immediately!
WARNING
Danger of poisoning by exhaust fumes!
Exhaust fumes contain toxic carbon monoxide that can lead to unconsciousness or death.
Always switch off the engine during maintenance work!
Task
Daily
before
operation
After the
first
20 hours
Weekly or
every
25 hours
Monthly
or every
100 hours
Annually
or every
300 hours
Clean the connections
Check the fuel:
- fuel level of tank
- tank for leaks
- lines for leaks
Checking engine oil level
Clean air filter
Changing the engine oil
Clean fuel filter
Check and clean the spark plug
Replace the spark plug
Maintenance GH 3500
22
7.2 Checking engine oil level
f Place the machine upright on a flat surface.
f Remove any dirt around the oil level dipstick.
f Remove the oil level dipstick (1) and wipe it with a clean, lint-free cloth.
f Screw the oil level dipstick all the way back in and pull it out again.
f Check: The motor oil level must be between the lower and upper marks.
f If necessary, pour new engine oil into the opening (2) until the upper mark is
reached on the oil level dipstick (see chapter Technical data for oil type).
f Screw in the oil level dipstick and tighten it by hand.
1
2
GH 3500 Maintenance
Operator's manual 23
7.3 Changing the engine oil
Note: The work area should be covered with a waterproof sheet to protect
the floor (protection of the environment).
f Place the machine upright on a flat surface.
f Bring the engine to a hand warm temperature, either by letting it cool down
or running it until it is warm.
f Switch off the engine.
f Remove any dirt around oil level dipstick (1) and oil drain plug (3).
f Place a sufficiently large container under the oil drain plug to catch the used
oil.
f Remove the oil level dipstick and wipe it with a clean, lint-free cloth.
f Use a screw wrench to remove the oil drain plug and drain the entire used oil.
Note: Avoid spilling oil. Remove any spilled oil immediately.
f Screw the oil drain plug back in and use a torque wrench to tighten it to
30 Nm.
f Pour new engine oil into the opening (2) until the upper mark is reached on
the oil level dipstick.
In doing so, screw the oil level dipstick all the way back in and pull it out again
repeatedly.
See the chapter Technical data for oil quantity and oil type.
Note: Avoid spilling oil. Remove any spilled oil immediately.
f Screw in the oil level dipstick and tighten it by hand.
Note: Dispose of the used oil in accordance with the applicable regulations.
1
2
3
Maintenance GH 3500
24
7.4 Cleaning the air filter / replacing the air filter inserts
The air filter is equipped with two air filter inserts.
Note: The air filter must be cleaned every day if conditions are adverse, dry,
and dusty.
Replace the air filter cartridges if it is no longer possible to remove the dirt.
f Unscrew the wing nut (1) and remove the cap (2).
f Clean the filter bracket around the air filter cartridges (with compressed air).
f Unscrew the inner wing nut (3) and remove air filter cartridges.
f Carefully remove the foam insert (4) from the paper insert (5).
f Check both parts for damage. Replace any damaged parts.
f Wash the foam insert with warm water and a mild soap solution. Rinse with
clear water. Let it dry.
f Clean the paper insert by knocking it gently and clean it with compressed air
from the inside to the outside.
f Reassemble it in reverse order or with new inserts. Tighten the wing nuts by
hand.
WARNING
Danger of fire and explosions
if the wrong cleaning agent is used.
Do not use gasoline or any other solvents to clean components.
CAUTION
Operating the engine without air filter can cause rapid engine wear.
Do not run the engine without an air filter.
2
4
5
1
3
GH 3500 Maintenance
Operator's manual 25
7.5 Cleaning the fuel dirt separator
f Place the machine upright on a flat surface.
f Close the fuel tap (1).
f Remove any dirt around the fuel dirt separator (2).
f Place a container under the fuel dirt separator to catch the fuel.
f Use an open-end wrench to remove the fuel dirt separator and empty it into
the container.
Note: Avoid spilling fuel. Remove any spilt fuel immediately.
f Clean the fuel dirt separator with gasoline.
f Insert the fuel dirt separator with the seal and use a torque wrench to tighten
it to 5 Nm.
Check for leaks:
f Open the fuel tap.
There must not be any leaking fuel.
Note: Dispose of the contents of the container in accordance with the appli-
cable regulations.
DANGER
Danger of fire and explosions by fuel!
Any fuel in open containers can ignite and cause severe burns.
Do not smoke, no open fire!
2
1
Maintenance GH 3500
26
7.6 Checking / cleaning / replacing the spark plug
f Remove the spark plug connector.
f Remove the spark plug with a spark plug wrench.
f Clean the electrodes with a wire brush.
f Check the isolator (2) – if damaged, replace the spark plug.
f Check and adjust the electrode gap (1) – see chapter Technical data for the
gap.
f Insert the spark plug and tighten it with a torque wrench.
WARNING
Hot exhaust!
Touching it can cause burns.
Only remove the spark plug when the engine has cooled down.
Torque [Nm] Spark plug
15
New spark plug
25
Used spark plug
CAUTION
A loose spark plug can damage the engine.
Always tighten the spark plug.
1
2
GH 3500 Troubleshooting
Operator's manual 27
8 Troubleshooting
Generator
Engine
Malfunction Cause Remedy
No voltage
(or unstable)
Cable damage or contact problem
Have it repaired
Short circuit in the stator coil Have coil replaced
Abnormal noises
(metallic noises or similar)
Shaft bearing defective Have bearing replaced
Contact between rotor and stator
Have it repaired
Vibrations Unstable position Move machine to a stable posi-
tion
Shaft bearing defective Have bearing replaced
Malfunction Cause Remedy
Engine does not start Fuel tank empty Top off with fuel
Fuel tap closed Open the fuel tap
Engine switch set to "OFF". Set the engine switch to "ON"
Motor oil level "too low"
because the machine is leaning (automatic oil shut off)
Position the machine horizontally
Motor oil level too low (automatic oil shut off)
Top off with engine oil
Spark plug Clean, set electrode gap, or
replace
Engine does not turn Engine damage Repair engine or have it
replaced
Engine not running smoothly Air filter dirty Clean air filter
Fuel filter dirty Clean fuel filter
Spark plug Clean, set electrode gap, or
replace
Technical data GH 3500
28
9 Technical data
Generator
Unit Value
Item number 0610079
Dimensions (L x W x H) mm 540 x 440 x 521
Net weight kg 39
Maximum output kVA 4.2
Continuous output kVA 3.2
Rated current A 41.2
Rated voltage V 42 3~
Frequency Hz 200
Output factor cos ϕ 0.8
Plug receptacles 2 x 42 V, 32 A
1 x 42 V, 63 A
GH 3500 Technical data
Operator's manual 29
Engine
Unit Value
Drive motor Air-cooled, single-cylinder, four-
stroke gasoline engine with automatic shutdown if there is insufficient oil
Engine type Wacker WM 210
Rated output (*)
* Equivalent to the installed power output in accordance with the directive 2000/14/EC
kW (PS) 5.1 (7.0) at 3500 1/min
Engine displacement cm
3
211
Fuel Type Regular gasoline, lead-free
(91 octane)
Fuel consumption l/h 1.9
Tank capacity (fuel) l 3.6
Spark plug Type NGK BPR6HS (Champion RL86C)
Electrode gap mm 0.3-0.5
Starting torque Nm 15 with new spark plug
25 with worn spark plug
Engine oil Type Grade SAE 10W-30 SE or higher
Oil quantity l 0.6
Tightening torque for oil drain
plug
Nm 30
Technical data GH 3500
30
EC Declaration of Conformity
Wacker Construction Equipment AG, Preußenstraße 41, 80809 München
certifies that the construction machine:
Type:
High-frequency generator
Model:
GH 3500
Machine type number:
0610079
Absolute installed power output:
3,2 kW
was assessed in accordance with the directive 2000/14/EC:
and was produced in accordance with the following directives:
2000/14/EC
89/336/EC
98/37/EC
73/23/EC
Conformity assessment procedure
At the following test
center
Measured sound
power level
Guaranteed sound
power level
Appendix VI VDE Prüf- und
Zertifizierungsinstitut
Certification office
Merianstraße 28
D-63069 Offenbach,
Germany
94 dB(A) 96 dB(A)
Dr. Stenzel
Head of Research and Development
Please keep this document in a safe place
DIN EN ISO 9001 Zertifikat
Wacker Construction Equipment AG - Preußenstraße 41 - 80809 München - Tel.: +49-(0)89-3 54 02-0 - Fax: +49-(0)89-3 54 02-390
Wacker Corporation - P.O. Box 9007 - Menomonee Falls, WI 53052-9007 - Tel.: +1-(1)(262)-255-0500 - Fax: +1-(1)(262)-255-0550 - Tel.: (800)770-0957
Wacker Asia Pacific Operations-Skyline Tower, Suite 2303, 23/F, 39 Wang Kwong Road, Kowloon Bay, Hong Kong-Tel.: +852 2406 6032-Fax: +852 2406 6021
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