FORLI' Italy GENERAL INDEX GB I D NL F SP ................................................ Pag. 1÷9 INDEX Description 1.0 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.3.4 2.0 2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.4 3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3 4.4 4.5 4.6 5.0 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 6.0 6.1 7.0 8.0 8.1 8.2 Page ................................................ Pag. 10÷18 ................................................ Pag. 19÷27 ................................................ Pag. 28÷36 ................................................ Pag. 37÷45 ................................................ Pag. 46÷54 Identification .................................................. 2 Manufacturer ..................................................... 2 Definitions .......................................................... 2 Transport - Handling - storage ........................... 2 Storage conditions ............................................. 2 Weight ............................................................... 2 Overall dimensions ............................................. 2 Handling ............................................................ 2 Installation ...................................................... 2 Authorised personnel ......................................... 2 Mounting the generator ...................................... 3 Electrical connections ........................................ 3 Connection of the battery recharger ................... 3 Connection of the starter battery ........................ 3 Connection of the remote control panel ............. 3 Installing the fuel tank ......................................... 3 Connection to gas canister ................................ 3 General operation ......................................... 4 Description of generator and functioning ............ 4 Safety advice ..................................................... 4 Noise levels ........................................................ 4 Instructions for use ...................................... 5 Starting the generator ........................................ 5 Stopping the generator ...................................... 5 Inherent risks ..................................................... 5 Improper use ..................................................... 5 Useful advices .................................................... 5 Troubleshooting ................................................. 5 Maintenance operations .............................. 6 Nature and frequency of checks ........................ 6 Maintenance operations which do not require qualified technicians ............................... 6 Maintenance operations which require qualified technicians ........................................... 6 Oil change ......................................................... 7 Air filter maintenance .......................................... 7 Spark plug maintenance .................................... 7 Regulating the voltage ........................................ 8 Inactivity and dismantling ........................... 8 Dismantling ........................................................ 8 Dealing with fire hazards ............................. 8 Technical data sheet .................................... 9 Technical specifications ..................................... 9 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. 1 FORLI' Italy 1.0 IDENTIFICATION 1.3.3 OVERALL DIMENSIONS See figg. 2, 3, 4 : Model 1000 A TYPE "A" INSTALLATION The identification plate of the machine is affixed outside the plate casing (see fig. 1). 1.1 MANUFACTURER mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm B C D E F G H 2500 530 605 640 385 290 295 30 360 87 96 222 28 605 30 295 650 430 305 220 3000 570 650 680 385 290 295 30 360 113 97 230 25 650 30 295 690 435 305 220 4000 660 740 770 475 355 310 62 -78 265 130 17 740 62 310 780 540 380 260 5500 700 --515 510 -------735 55 370 770 505 550 WTA srl Via Virgilio, 3 47100 FORLI' - ITALY P. IVA 00718330400 470 535 565 320 315 260 27 -65 65 225 36 535 27 260 590 385 335 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 TYPE "B" INSTALLATION OPENING DIM. I L M N O P Q X Y Z 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. IMPORTANT Draws attention to situations which may cause malfunctioning or damage to the machine. Air intake area cm2 220 1.3.4 HANDLING 1.3 TRANSPORT - HANDLING - STORAGE 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. 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. DANGER Strictly observe the accident prevention precautions and safety regulations during lifting and transport, and always use machines with a higher maximum capacity than the load to be lifted. 1.3.2 WEIGHT Gross weight (including packing): Mod. 1000 .......................................... Kg Mod. 2500 .......................................... Kg Mod. 3000 .......................................... Kg 50 62 71 2.0 2.1 INSTALLATION AUTHORISED PERSONNEL Mod. 4000 .......................................... Kg 114 Mod. 5500 .......................................... Kg 140 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 2 FORLI' Italy 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. 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). DANGER The instructions given in sections 2.2 - 2.3 - 2.4 are addressed to qualified technicians only. 2.2 MOUNTING THE GENERATOR Mod. 1000 2500 3000 4000 5500 Cross-section Cross-section mm2 -230 V mm2-12 V 1.5 6 2.5 2.5 2.5 2.5 4 2.5 4 2.5 6m 10 10 10 10 16 >6m 16 16 16 16 25 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. Power cables Battery recharger 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 3 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. 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. IMPORTANT Model 5500 does not need fuel tank, since it is standard fitted inside the genset casing. CONNECTION TO GAS CANISTER 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) 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 resul ...