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- Page 1 Translated from German to English - www.onlinedoctranslator.com operating instructions Inverter IG-4000 – power generator OA IG-4000 original operating instructionsWork on and with this machine may only be carried out by qualified persons! manufacturer's copy...
- Page 2 Project ID: IG 4000 Rev. status: 2023-02-20 © LUMAG GMBH Rudolf-Diesel-Str. 1a 84375 Kirchdorf am Inn Tel.: +49 8571 92556-0 Fax: +49 8571 92556-19 E-mail:info@lumag-maschinen.de Internet:www.lumag-maschinen.de...
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Page 3: Table Of Contents
Operating Instructions Inverter IG- 4000 Overview Overview ..................... 6 scope of delivery ................7 Accesories ..................7 change log ....................8 Information about the operating instructions ........9 General Information ................ 9 symbols, abbreviations, terms ............. 11 explanation of symbols ..............12 Warranty / Guarantee / Customer Service ....... - Page 4 Safety instructions for use ............51 preparation for deployment ............54 Operation Inverter IG-4000 ............54 Start inverter IG-4000 ..............54 Turn off the inverter IG-4000............56 Emergency shutdown ..............57 maintenance .................... 58 10.1 Safety instructions for maintenance .......... 58 10.2...
- Page 5 Operating Instructions Inverter IG- 4000 Overview list of figures .................... 79 list of tables ....................80 note ......................81...
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Page 6: Overview
Operating Instructions Inverter IG- 4000 Overview 1 Overview Fig. 1: Overview of Inverter IG-4000 generator – front and rear view... -
Page 7: Scope Of Delivery
Operating Instructions Inverter IG- 4000 Overview scope of delivery Check the contents for completeness and integrity. ► documentation ► machine unit with gasoline engine ► Carrying handle – 2 pieces (not shown) ► Swivel castor without brake – 2 pieces (A) ►... -
Page 8: Change Log
Operating Instructions Inverter IG- 4000 change log 2 change log Date amended by Section reason for the change Tab. 1: Change log... -
Page 9: Information About The Operating Instructions
4000 Information about the operating instructions 3 Information about the operating instructions General Information product Designation statement machine designation inverter generator model/type IG-4000 serial number 06004xxxxx year of construction 2022 Tab. 2: Product information Manufacturer Designation statement Pursue LUMAG GmbH Street, No. - Page 10 Operating Instructions Inverter IG- 4000 Information about the operating instructions This operating manual describes the safe and proper use of the machine. The specified safety information and instructions, as well as the local accident prevention regulations and general safety regulations applicable to the area of use, must be observed.
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Page 11: Symbols, Abbreviations, Terms
ApplicableNot applicable □ Observe the supplier’s operating instructions! The IG-4000 inverter is powered by a combustion engine. Read the supplier's operating instructions before starting any work! Terms and Conditions General terms and conditions of business Do not dispose of electrical devices and tools in household waste! →European Directive 2012/19/EU on waste electrical and electronic... -
Page 12: Explanation Of Symbols
Operating Instructions Inverter IG- 4000 Information about the operating instructions explanation of symbols warning and safety instructions Warning and safety instructions in the manual are indicated by pictograms marked and highlighted in a gray block. Warning and safety instructions that draw attention to basic dangers are also introduced with signal words that express the extent of the damage. - Page 13 Operating Instructions Inverter IG- 4000 Information about the operating instructions tips and recommendations A NOTICE! … highlights tips and recommendations as well as information for efficient and trouble-free operation. Special safety instructions To indicate special dangers, in connection with The following pictograms are used for safety instructions: …...
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Page 14: Warranty / Guarantee / Customer Service
LUMAG guarantees flawless quality and, without prejudice to the statutory warranty, provides a guarantee in the event of material or manufacturing defects. The guarantee for LUMAG products is 24 months for exclusively private use, and 12 months for commercial or professional use or rental, from the date of delivery. -
Page 15: Declaration Of Conformity
E-mail:info@lumag-maschinen.de declaration of conformity The design and construction of the IG-4000 inverter complies with the essential health and safety requirements of the EC Machinery Directive, including the amendments in force at the time of declaration. The declaration of conformity is enclosed with these operating instructions ( Appendix). -
Page 16: Security
Failure to follow the instructions, warnings and safety notices listed may result in significant dangers. Intended Use The IG-4000 inverter is designed and built for commercial and private use and exclusively for the intended purpose described here: The IG-4000 inverter is intended exclusively for the following commercial... -
Page 17: Foreseeable Misuse
Misuse of the machine can lead to dangerous situations for persons and cause serious damage to property. – Avoid any misuse of the machine. – Never use the IG-4000 inverter: • use other than as intended ( Intended Use) •... -
Page 18: Responsibilities
IG-4000 inverter have read and understood the operating instructions. In addition, the operator must train the personnel at regular intervals in how to use the IG-4000 inverter and inform them of the potential dangers. -
Page 19: Responsibility Of The Staff
Any work on the IG-4000 inverter may only be carried out by persons who can perform their work properly and reliably and who meet the requirements specified for their activity. -
Page 20: Special Safety Instructions
Operating Instructions Inverter IG- 4000 Security 4.6 Special safety instructions To indicate particular dangers, the following pictograms are used in conjunction with safety instructions: … indicates hazards caused by electrical current. Failure to follow the safety instructions may result in serious or fatal injuries. -
Page 21: Qualification Requirements
– Any activities may only be carried out by persons who have the necessary training, knowledge and experience. operating personnel The IG-4000 inverter may only be transported, operated, equipped and maintained by trained persons who have been thoroughly and verifiably informed by the operator about the tasks assigned to them and the possible dangers. -
Page 22: Instruction
IG-4000 inverter. ► has not received any instruction from the operator or his authorized representative for their work on the IG-4000 inverter and/or has not been commissioned to do so. -
Page 23: Personal Protective Equipment (Ppe)
Operating Instructions Inverter IG- 4000 Security Personal protective equipment (PPE) Wear during all work protective work clothing Tight-fitting work clothing with low tear resistance, with tight sleeves and no protruding parts, primarily to protect against being caught by moving machine parts. Do not wear rings, necklaces or other jewelry. -
Page 24: Residual Risks
Security 4.10 residual risks The IG-4000 inverter has been subjected to a risk assessment. The hazards identified have been eliminated as far as possible and identified risks have been reduced. However, the IG-4000 inverter still poses residual risks, which are described in the following section. -
Page 25: Risksdue To Electrical Hazards
Operating Instructions Inverter IG- 4000 Security 4.10.2 Risks from electrical hazards Electrical current DANGER! Danger to life from electric current! Touching live parts will result in death. Damage to the insulation or individual components can be life-threatening. – Before starting any work on the electrical system, switch off the electrical machine. -
Page 26: Risks From Materials And Substances
– If any defects are detected, stop the IG-4000 inverter immediately and have it repaired by qualified personnel. – Do not reuse fuel hoses that have already been used. - Page 27 Operating Instructions Inverter IG- 4000 Security fuels, gasoline WARNING! Risk of fire and explosion when handling fuels! Fuels can burn explosively and cause poisoning or skin irritation. – Observe the fuel manufacturer’s safety instructions. – Do not refuel the machine in enclosed spaces. –...
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Page 28: Risks From Neglecting Ergonomic Principles
Operating Instructions Inverter IG- 4000 Security 4.10.7 Risks from neglecting ergonomic principles Unhealthy posture, special exertion CAUTION! Health damage caused by unhealthy posture! Incorrect lifting and unnatural posture while working can cause health problems. – Always have several people lift heavy components. –... -
Page 29: Fire Protection
Measure / Condition to be observed Inverter IG-4000 To prevent the formation of an ignitable atmosphere when passing flammable media, check regularly for leaks (e.g. with soft soap or similar). The IG-4000 inverter must not be operated in enclosed spaces. - Page 30 – Appoint responsible supervisors. – Remove the fuel tank from the IG-4000 inverter and take it out of the welding workshop. Drain any remaining fuel, flush the lines if necessary and ensure adequate ventilation. – Seal open grease and oil lines and connections.
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Page 31: Safety Devices
IG-4000 inverter must be restarted. The motor switch (1) in the OFF position also prevents the IG-4000 inverter (motor) from starting. To restart, set the motor switch to the ON position, then start the motor as described in →... -
Page 32: Securing Against Reactivation
Turn the fuel tap to the OFF/CLOSED position. Set the energy saving switch to the OFF position. Attach a warning label to the IG-4000 inverter and write the name of the person responsible who is authorized to switch the IG-4000 inverter back on on the warning label ( Fig. -
Page 33: Signage
Operating Instructions Inverter IG- 4000 Security 4.15 signage The following symbols and information signs are located on the IG-4000 inverter to draw attention to possible hazards and important information: Pos. Sign Numbe Meaning Safety instructions!! Reference to various dangers when handling the IG- 4000 inverter. - Page 34 Operating Instructions Inverter IG- 4000 Security Pos. Sign Numbe Meaning WARNING! Risk of fire and explosion! Fuel and its vapors are highly flammable. Turn off the engine and allow it to cool before refueling. Check for leaks and spilled gasoline, collect and dispose of any residue.
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Page 35: Tab. 8: Signs On The Machine
Operating Instructions Inverter IG- 4000 Security Pos. Sign Numbe Meaning WARNING! Noise! Take noise protection measures, wear hearing protection during operation, do not operate in enclosed spaces. The engine is delivered without oil! Before first use, fill the engine sufficiently with engine oil (SAE 10W-30) ( Filling engine oil). -
Page 36: Behavior In The Event Of Danger And Accidents
Operating Instructions Inverter IG- 4000 Security 4.16 Behavior in the event of danger and accidents ► Preventive measures Always be prepared for accidents and fires. ► Keep first aid equipment (first aid kit, blankets, etc.) and fire extinguishers close at hand. ►... -
Page 37: Technical Data
Operating Instructions Inverter IG- 4000 Technical data 5 Technical data overview drawings Fig. 4: Overview drawing... -
Page 38: General Information
Dimensions (L x W x H) 660 x 470 x 528 dead weight 47.6 Tab. 9: Technical data Inverter IG-4000 engine specification Value Unit gasoline engine drive 4-stroke OHV, 1-cylinder 170F displacement cm³... -
Page 39: Operating Conditions
Maintenance intervals, min. service life, max. 10 years Tab. 12: Permissible operating times and service life nameplate Inverter IG-4000 Fig. 5: Type plate 1 Model / Description 2 year of manufacture / serial number 3 Max. Power 4 continuous power... -
Page 40: Structure And Function
Operating Instructions Inverter IG- 4000 structure and function 6 structure and function assembly overview Fig. 6: Overview of the entire machine 1 engine switch 7 choke 15 carrying handle (2x) 22s p a r k p l u g c o n n e c t o r 2 Show 8 AC-RESET button 230V 16 Tank cap with ventilation 23 Air filter 2a Operating display9... -
Page 41: Functional Description
The IG-4000 inverter works very efficiently in the partial load range. If less power is required, the machine works very quietly and consumes less fuel because, unlike conventional power generators, the device can regulate... -
Page 42: Description Of The Assembliesand Components
► Spark plug (22) control panel (21) All switching operations of the IG-4000 inverter take place on the control panel (21). The sockets for the 230 V, DC 12 V, parallel and USB connections are also located here. switching operations –... - Page 43 The gasoline engine is located in the housing of the IG-4000 inverter and supplies the connected devices with energy during operation. tank cap with ventilation...
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Page 44: Transport
Operating Instructions Inverter IG- 4000 transport 7 transport A NOTICE! Transport is carried out by a forwarding agent commissioned by the manufacturer. DANGER! Property damage due to incorrect lifting and transport! Incorrect attachment of loads, inadequate transport safety devices and poor positioning of components can cause serious damage to the machine. -
Page 45: Transport Inspection
Operating Instructions Inverter IG- 4000 transport ► staff Transport work without the aid of lifting or conveying equipment that requires supervision may be carried out by trained personnel commissioned by the operator. ► Transport work with the assistance of lifting or conveying equipment that requires monitoring may only be carried out by trained, authorized and qualified personnel appointed by the operator. -
Page 46: Transport And Storage
Operating Instructions Inverter IG- 4000 transport Meaning of transport symbols The following transport symbols can be found on transported goods: Above The arrowheads indicate the top of the goods being transported. They must point upwards, otherwise the contents may be damaged. Fragile Indicates transported goods with fragile or sensitive contents. - Page 47 Operating Instructions Inverter IG- 4000 transport transport or relocation CAUTION! Danger of burns from hot surfaces (engine)! Contact with hot components can cause burns. – When working near hot components Wear protective work clothing and gloves. – Before carrying out any work, allow the hot components to cool down to below +40 °C.
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Page 48: Commissioning
The subsoil has sufficient load-bearing capacity for the IG-4000 inverter. ► The surface must be flat and dry to prevent tipping or slipping. ► Install the IG-4000 inverter at least 1 m away from buildings and connected devices.Turning, tilting or changing location during operation is prohibited! -
Page 49: Prerequisites For Commissioning
− Be careful when handling fuel and follow the manufacturer's instructions ( safety data sheet) Prerequisites for commissioning In order to operate the IG-4000 inverter, the following conditions must be met: ► Filling engine oil: − Open maintenance cover (18) −... -
Page 50: Preparations For Commissioning
Incorrect oil and/or fuel filling will cause irreparable damage to the engine and void the warranty. 8.3.1 preparations for commissioning The IG-4000 inverter can be put into operation without any special effort and without any special installations. A NOTICE! If you have any questions or problems before commissioning, please contact us by email:info@lumag-maschinen.deor by phone at +49... -
Page 51: Service
DANGER! Danger to life from electric current! A lightning strike to the IG-4000 inverter or a voltage surge from power lines can be life-threatening. – If a thunderstorm is imminent, stop working outdoors immediately and leave the work area at least 100 m away from the machine. -
Page 52: Fig. 10: Grounding
Danger to life from electric current! Inverter IG-4000 never: – park in water and/or operate on very wet ground – Do not touch the IG-4000 inverter or cable with wet hands or barefoot – always use a residual current device (RCD) on damp or highly conductive surfaces –... - Page 53 Operating Instructions Inverter IG- 4000 service Behavior in an Emergency ► If burns occur, immediately provide the affected person with self- contained breathing apparatus, remove to fresh air, keep at rest and warm. Consult a doctor. ► If breathing stops, initiate artificial respiration. ►...
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Page 54: Preparation For Deployment
Engine oil is filled ( Filling) fuel is filled ( refueling) the IG-4000 inverter is installed on a clean and level surface in a well-ventilated area Before starting work, make sure that: there is sufficient distance to flammable objects and materials (at... -
Page 55: Fig. 11: Starting The Motor And Inverter Ig-4000
4000 service Start the motor and inverter IG-4000 To start the motor and the IG-4000 inverter, perform the following steps ( Fig. 11): Set the energy saving switch (6) to the OFF position. The IG-4000 inverter runs at maximum speed. -
Page 56: Turn Off The Inverter Ig-4000
– Before carrying out any work, allow the hot components to cool down to below +40 °C. To switch off the motor and the IG-4000 inverter, perform the following steps ( Fig. 12): Set the energy saving switch (6) to the OFF position. -
Page 57: Emergency Shutdown
Emergency shutdown In case of danger: The engine switch (1) in the OFF position switches off the IG-4000 inverter and also prevents the engine from starting or re-starting. To restart the engine, turn the engine switch to the ON position and then start the engine as described in Commissioning / Operation. -
Page 58: Maintenance
When working on individual components, people can be injured by unexpected switching on. – Before carrying out any work on the IG-4000 inverter, switch off the engine, allow it to cool down and secure it against being switched on again. To do this, remove the spark plug connector. - Page 59 Operating Instructions Inverter IG- 4000 mainten ance CAUTION! Danger of suffocation and poisoning! Operation in enclosed spaces is prohibited. Contact with carbon monoxide (exhaust gases) can cause suffocation and/or poisoning. – Maintenance and repair work should only be carried out in a suitable environment;...
- Page 60 Operating Instructions Inverter IG- 4000 mainten ance WARNING! Risk of injury from oils and fats! Oils and fats contain harmful components and can lead to poisoning or skin irritation. – Avoid contact with skin and eyes. – Avoid spillage and misting. –...
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Page 61: Engine Oil Change
Operating Instructions Inverter IG- 4000 mainten ance 10.2 engine oil change A NOTICE! The engine oil must be changed after the first 5 hours of operation. Change the engine oil when the engine is warm (the oil will then drain quickly and completely). Dispose of in accordance with environmental regulations. -
Page 62: Maintenance Plan
Operating Instructions Inverter IG- 4000 mainten ance 10.3 maintenance plan The following sections describe the maintenance work required to ensure optimal and trouble-free operation. ► If increased signs of wear on the components are detected during regular inspections, shorten the maintenance intervals based on the actual signs of wear! ►... -
Page 63: Change/Clean Air Filter
Operating Instructions Inverter IG- 4000 mainten ance 10.3.1 Change / clean air filter WARNING! Risk of fire and explosion when handling flammable liquids! Fuels can burn explosively and cause poisoning or skin irritation. – Do not clean the air filter element with flammable liquids To clean and/or change the air filter (23) or insert: Loosen the screws (4 pieces) of the engine cover and remove the engine cover. -
Page 64: Check/Change/Clean Spark Plug
Operating Instructions Inverter IG- 4000 mainten ance 10.3.2 Check / change / clean spark plug WARNING! Danger of burns! The engine and parts (e.g. exhaust silencer or cooling fins) heat up considerably during operation. Observe cooling times – wear heat-resistant work gloves To check, clean and/or replace the spark plug: Loosen the screws (4 pieces) of the engine cover and remove the engine cover. -
Page 65: Maintenance Log
Operating Instructions Inverter IG- 4000 mainten ance 10.4 maintenance log The required maintenance intervals depend on the intensity of use of the machine at the operator's site and the resulting actual signs of wear. In order to be able to adapt the maintenance intervals to these conditions of use, the general condition of the machine as a whole and of the individual assemblies and components must be recorded during regular and, if necessary, unscheduled maintenance work. -
Page 66: Machineclean
After cleaning, lubricate or oil all lubrication points. DANGER! After cleaning or if the IG-4000 inverter is not in use for a long period of time, all moving parts must be greased or oiled. -
Page 67: Measures After Maintenance
Operating Instructions Inverter IG- 4000 mainten ance 10.5 Measures after maintenance After completing maintenance, perform the following steps before switching on: Check that all previously loosened screw connections are tight. Check that all previously removed guards and covers are properly reinstalled. Ensure that all tools, materials and other equipment used have been removed from the work area. -
Page 68: Disorders
When working on individual components, people can be injured if the power supply is switched on unexpectedly. – Before carrying out any work on the IG-4000 inverter, switch off the engine, allow it to cool down and secure it against being switched on again. To do this, remove the spark plug connector. - Page 69 Operating Instructions Inverter IG- 4000 disorders fuels for combustion engines and oils WARNING! Danger of serious damage to health if spray mist or liquid drops are inhaled, touched or swallowed! Fuels contain components that are extremely harmful to health and can lead to poisoning, lung damage, genetic changes and severe skin irritation.
- Page 70 Operating Instructions Inverter IG- 4000 disorders CAUTION! Danger of burns from hot surfaces! Contact with hot components can cause burns. – Wear protective clothing and gloves when carrying out maintenance and repair work near hot components. – Allow hot components to cool to ambient temperature before starting work.
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Page 71: Behavior In The Event Of Disturbances
Operating Instructions Inverter IG- 4000 disorders WARNING! Risk of injury from oils and fats! Oils and fats contain harmful components and can lead to poisoning or skin irritation. – Avoid contact with skin and eyes. – Avoid spillage and misting. –... -
Page 72: Troubleshooting
Operating Instructions Inverter IG- 4000 disorders 11.1.3 troubleshooting ► Only persons who have been fully instructed by the manufacturer in the structure and functioning of the machine, trained for the required tasks and authorized by the operator in accordance with the specifications of this operating manual may be commissioned to rectify the fault. -
Page 73: Disturbance
Consumers connected to the Indicator light for overload is a reduce load specialist staff IG-4000 inverter do not start Connected consumers are Repairing defective devices defective Air filter is dirty Clean or replace air filter specialist staff... -
Page 74: Attachment
According to the provisions of the EC Machinery Directive 2006/42/EC EMC Directive 2014/30/EU Outdoor Directive 2000/14/EC the company LUMAG GmbH Rudolf-Diesel-Straße 1a D-84375 Kirchdorf a.Inn Phone: +49 8571 / 92 556-0 Fax: +49 8571 / 92 556-19 that the product... -
Page 75: Circuit Diagram
Operating Instructions Inverter IG- 4000 Attach ment 12.2 circuit diagram Fig. 17: Circuit diagram... -
Page 76: Assembly
Attach ment 12.3 assembly 12.3.1 Install carrying handles The Inverter IG-4000 is equipped with 2 carrying handles. ► The carrying handles are screwed onto the device via mounting holes at the front and back. To mount the carrying handles: 1. Place the handle in a horizontal position and insert it into the two holders. -
Page 77: Installing Castors
Requirement: The carrying handles are mounted ( Assembly / Mounting the carrying handles 12.3.1) To mount the castors: 1. Place a piece of timber underneath and tilt the IG-4000 inverter slightly. 2. Respectively Screw 2 swivel castors onto the front and back of the device using the included hexagon socket screws. -
Page 78: Moredocuments
Operating Instructions Inverter IG- 4000 Attach ment 12.4 Additional documents ► Exploded drawings ( www.lumag-maschinen.de) ► Parts lists/spare parts lists ( www.lumag-maschinen.de) ► Circuit diagram ( www.lumag-maschinen.de) - Page 79 13 list of figures Fig. 1: Overview of Inverter IG-4000 generator – front and rear view ................6 Fig. 2: Position engine switch to “OFF” ........................31 Fig. 3: Example of a warning sign to prevent re-activation ..................32 Fig.
- Page 80 Tab. 7: Fire protection, required operator-side technical protective measures ............29 Tab. 8: Signs on the machine ............................33 Tab. 9: Technical data Inverter IG-4000 ........................38 Tab. 10: Technical data engine ............................38 Tab. 11: Operating conditions, working range ......................39 Tab.
- Page 81 Operating Instructions Inverter IG- 4000 note 15 note...
- Page 83 Operating Instructions Inverter IG- 4000 note...
- Page 84 Project ID: IG 4000 Rev. status: 2023-02-20 © LUMAG GMBH...
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