Wacker Neuson GH 3500 Operator's Manual
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.
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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.
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