Wacker Neuson GV 7000A, GV 7003A Operator's Manual

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Page 1

www.wackergroup.com

0157387en 004

1106

Generator

GV 7000A GV 7003A

OPERATOR’S MANUAL

0157387EN

Page 2

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.

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GV 7000A/7003A Table of Contents

1. Foreword 3

2. Safety Information 4

2.1 Operating Safety .................................................................................. 5

2.2 Operator Safety while using Internal Combustion Engines .................. 6

2.3 Service Safety ...................................................................................... 7

2.4 Label Locations .................................................................................... 8

2.5 Safety and Operating Labels ................................................................ 9

3. Technical Data 11

3.1 Generator ........................................................................................... 11

3.2 Engine ................................................................................................ 13

3.3 Sound Specifications .......................................................................... 13

4. Operation 14

4.1 Determining Power Requirements ..................................................... 14

4.2 Outdoor Installation ............................................................................ 16

4.3 Indoor Installation ............................................................................... 16

4.4 Generator Derating ............................................................................. 17

4.5 Use of Extension Cords ...................................................................... 18

4.6 Grounding the Generator ................................................................... 20

4.7 Operating Heavy Loads ...................................................................... 20

4.8 Control Panel ...................................................................................... 21

4.9 Before Starting ................................................................................... 23

4.10 To Start ............................................................................................... 24

4.11 To Stop ............................................................................................... 24

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Table of Contents GV 7000A/7003A

5. Maintenance 25

5.1 Engine Maintenance ............................................................................25

5.2 Periodic Maintenance Schedule ..........................................................25

5.3 Engine Oil ............................................................................................26

5.4 Air Cleaner ..........................................................................................27

5.5 Spark Plug ...........................................................................................28

5.6 Engine Speed ......................................................................................29

5.7 Storage ................................................................................................30

5.8 Transport .............................................................................................30

5.9 Troubleshooting ...................................................................................31

5.10 Electrical Schematic—GV 7000A ........................................................32

5.11 Electrical Schematic—GV 7003A ........................................................33

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1. Foreword

Foreword

This manual provides information and procedures to safely operate and maintain this Wacker model. For your own safety and protection from injury, carefully read, understand and observe the safety instructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose this manual or need an additional copy, please contact Wacker Corporation. This machine is built with user safety in mind; however, it can present hazards if improperly operated and serviced. Follow operating instructions carefully! If you have questions about operating or servicing this equipment, please contact Wacker Corporation.

The information contained in this manual was based on machines in production at the time of publication. Wacker Corporation reserves the right to change any portion of this information without notice.

All rights, especially copying and distribution rights, are reserved.

No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission from Wacker Corporation.

Any type of reproduction or distribution not authorized by Wacker Corporation represents an infringement of valid copyrights and will be prosecuted. We expressly reserve the right to make technical modifications, even without due notice, which aim at improving our machines or their safety standards.

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Safety Information GV 7000A / 7003A

2. Safety Information

This manual contains DANGER, WARNING, CAUTION, and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

DANGER

WARNING

CAUTION

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION: Used without the safety alert symbol, CAUTION indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Note: Contains additional information important to a procedure.

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GV 7000A / 7003A Safety Information

2.1 Operating Safety

BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR DEATH TO UTILITY WORKERS!

DANGER

WARNING

Improper connection of generator to a building's electrical system can allow electrical current from the generator to backfeed into utility lines. This may result in electrocution of utility workers, fire, or explosion. Connections to a building's electrical system must be made by a qualified electrician and comply with all applicable laws and electrical codes.

If connected to a building's electrical system the generator must meet the power, voltage, and frequency requirements of the equipment in the building. Differences in power, voltage, and frequency requirements may exist and improper connection may lead to equipment damage, fire, and personal injury or death.

Familiarity and proper training are required for the safe operation of equipment. Equipment operated improperly or by untrained personnel can be dangerous. Read the operating instructions contained in both this manual and the engine manual and familiarize yourself with the location and proper use of all controls. Inexperienced operators should receive instruction from someone familiar with the equipment before being allowed to operate the machine.

2.1.1 NEVER operate the generator when open containers of fuel, paint, or other flammable liquids are near.

2.1.2 NEVER operate the generator, or tools attached to the generator, with wet hands.

2.1.3 NEVER use worn electrical cords. Severe electrical shock and equipment damage may result.

2.1.4 NEVER run the electrical cords under the generator, or over vibrating or hot parts.

2.1.5 NEVER enclose or cover the generator when it is in use or when it is hot.

2.1.6 NEVER overload the generator. The total amperage of the tools and equipment attached to the generator must not exceed the load rating of the generator.

2.1.7 NEVER operate the machine in snow, rain, or standing water.

2.1.8 NEVER allow untrained personnel to operate or service the generator. The generator set should be set up by a trained electrician.

2.1.9 ALWAYS store the equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children.

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Safety Information GV 7000A / 7003A

2.1.10 ALWAYS be sure the machine is on a firm, level surface and will not tip, roll, slide, or fall while operating.

2.1.11 ALWAYS transport the generator in an upright position.

2.1.12 ALWAYS keep the machine at least one meter (three feet) away from structures, buildings, and other equipment during use.

2.1.13 ALWAYS keep the area immediately surrounding and underneath the machine clean, neat, and free of debris and combustible materials. Make sure that the area overhead is clear of debris that could fall onto or into the machine or exhaust compartment.

2.1.14 ALWAYS remove all tools, cords, and other loose items from the generator before starting it.

2.1.15 DO NOT ground this generator.

2.2 Operator Safety while using Internal Combustion Engines

Internal combustion engines present special hazards during operation and fueling. Read and follow the warning instructions in the engine owner’s manual and the safety guidelines below. Failure to follow the

DANGER

warnings and safety guidelines could result in severe injury or death.

2.2.1 DO NOT run the machine indoors or in an enclosed area such as a deep trench unless adequate ventilation, through such items as exhaust fans or hoses, is provided. Exhaust gas from the engine contains poisonous carbon monoxide gas; exposure to carbon monoxide can cause loss of consciousness and may lead to death.

2.2.2 DO NOT smoke while operating the machine.

2.2.3 DO NOT smoke when refueling the engine.

2.2.4 DO NOT refuel a hot or running engine.

2.2.5 DO NOT refuel the engine near an open flame.

2.2.6 DO NOT spill fuel when refueling the engine.

2.2.7 DO NOT run the engine near open flames.

2.2.8 DO NOT start the engine if fuel has spilled or a fuel odor is present. Move the generator away from the spill and wipe the generator dry before starting.

2.2.9 ALWAYS refill the fuel tank in a well-ventilated area.

2.2.10 ALWAYS replace the fuel tank cap after refueling.

2.2.11 ALWAYS check the fuel lines and the fuel tank for leaks and cracks before starting the engine. Do not run the machine if fuel leaks are present or the fuel lines are loose.

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GV 7000A / 7003A Safety Information

2.3 Service Safety

Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. If

WARNING

2.3.1 DO NOT use gasoline or other types of fuels or flammable solvents to

2.3.2 DO NOT attempt to clean or service the machine while it is running.

2.3.3 DO NOT modify the equipment without the express written approval of

2.3.4 DO NOT allow water to accumulate around the base of the machine.

the generator is experiencing problems or is being serviced, attach a “DO NOT START” sign to the control panel to notify other people of its condition.

clean parts, especially in enclosed areas. Fumes from fuels and solvents can become explosive.

the manufacturer.

If water is present, move the machine and allow the machine to dry before servicing.

2.3.5 DO NOT service the machine if your clothing or skin is wet.

2.3.6 DO NOT allow untrained personnel to service this equipment. Only trained electrical technicians should be allowed to service the electrical components of this equipment.

2.3.7 ALWAYS keep the machine clean and labels legible. Replace all missing and hard-to-read labels. Labels provide important operating instructions and warn of dangers and hazards.

2.3.8 ALWAYS replace the safety devices and guards after repairs and maintenance.

2.3.9 ALWAYS let the engine cool before transporting or servicing it.

2.3.10 ALWAYS keep hands, feet, and loose clothing away from the moving parts on the generator and engine.

2.3.11 ALWAYS turn the engine off before servicing the machine. If the engine has electric start, disconnect the negative terminal on the battery before servicing the machine.

2.3.12 ALWAYS keep the fuel lines in good condition and properly connected. Leaking fuel and fumes are extremely explosive.

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Safety Information GV 7000A / 7003A

2.4 Label Locations

ISSINCI

GASOLINA

PETROL

HOT !

CHAUD !

BENZIN

HEISS !

CALDO !

wc_gr001298

DANGER

GEFAHR

PELIGRO

DANGER

GEFAHR

PELIGRO

DANGER

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GV 7000A / 7003A Safety Information

2.5 Safety and Operating Labels

Wacker machines use international pictorial labels where needed. These labels are described below:

Label Meaning

WARNING!

HOT !

CHAUD !

HEISS !

CALDO !

Hot surface!

Close the choke.

GASOLINA

PETROL

DANGER

GEFAHR

PELIGRO

DANGER

Gasoline

ISSINCI

BENZIN

Potential Earth.

WARNING! Electric shock will cause serious injury or death.

WARNING! Electric shock hazard. Read operator’s manual for instructions.

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Safety Information GV 7000A / 7003A

151710

Ins. class

COS

class

odel

Seria

GENE

ISO 8528

ITALY

Label Meaning

DANGER!

DANGER

GEFAHR

PELIGRO

DANGER

Asphyxiation hazard. Read the operator’s manual for instructions.

DANGER! No sparks, flames or burning objects near machine.

Fuel valve

Item No

Guaranteed sound power level in dB(A)

A nameplate listing the model number, item number, revision number, and serial number is

Rev

l N

MADE

RATING SET

attached to each unit. Please record the information found on this plate so it will be available should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model number, item number, revision number, and serial number of the unit.

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GV 7000A/7003A Technical Data

3. Technical Data

3.1 Generator

Item No. 0009348 0009353 0009358 0009363

GV 7000A Generator

Maximum Output

Continuous Output

kVA

6.05

5.5

Type Single voltage, single phase.

Brushless, capacitor regulator system

AC Voltages Available

Frequency

Volts

phase

230

1ø

Power Factor 0.9

AC receptacles: 230V, 16Amp Schuko 230V, 16Amp French 230V, 16Amp Swiss 230V, 16Amp CEE

230V, 32Amp Schuko 230V, 32Amp French 230V, 32Amp Swiss 230V, 32Amp CEE

Quantity

Main Circuit Breaker

Dimensions L x W x H

Weight (dry)

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Amp

mm (in.)

Kg (lbs.)

735 x 510 x 520 (29 x 20 x 20.5)

72 (159)

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Technical Data GV 7000A/7003A

Item No. 0009349 0009354 0009359 0009364

GV 7003A Generator

Maximum Output

Continuous Output

kVA

7.45

7.1

Type Dual voltage, multiple phase,

brush-type, compound regulator system

AC Voltages Available

Frequency

Volts

phase

230/1ø 400/3ø

Power Factor 0.8

AC receptacles: 230V, 16Amp Schuko 230V, 16Amp French 230V, 16Amp Swiss 230V, 16Amp CEE

400V, 16Amp CEE 400V, 16Amp Swiss

Main Circuit Breaker

Quantity

Amp

10, 12, 10 2-Pole

Dimensions L x W x H

Weight (dry)

mm (in.)

Kg (lbs.)

735 x 510 x 520 (29 x 20 x 20.5)

81 (179)

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GV 7000A/7003A Technical Data

3.2 Engine

GV 7000A GV 7003A

Engine

Engine Make Honda

Engine Model GX390K1-VPX4

Rated Power

kW (Hp)

8.3 (11.1)

Spark Plug BPR6ES / W20EPR-U

Electrode Gap

Engine Speed - full load

Engine Speed - no load

Air Cleaner

Engine Lubrication

Engine Oil Capacity

Fuel

Fuel Tank Capacity

Fuel Consumption

mm (in.)

rpm

type

oil grade

l (qts.)

type

l (gal.)

l (qts.)/hr.

0.7 - 0.8 (0.028 - 0.031)

3000 ± 100

3100 ± 100

Oil-wetted foam element

SAE 10W30 service class SJ

1.1 (1.2)

Regular unleaded gasoline

11 (3)

2.15 (2.27) 1.98 (2.09)

3/4 COP*

Running Time

hrs.

5.1 5.6

3/4 COP*

* Continuous Operating Power

3.3 Sound Specifications

The required sound specification, Paragraph 1.7.4.f of 89/392/EEC Machinery Directive, is:

• guaranteed sound power level (LWA) = 97 dB(A).

This sound value was determined according to ISO 3744 for the sound power level (LWA).

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Operation GV 7000A/7003A

4. Operation

4.1 Determining Power Requirements

Wacker generator Model GV 7000A is designed to operate singlephase, 50 Hertz appliances running at 230 VAC. Model GV 7003A is

designed to operate single phase, 50 Hertz appliances running at 230VAC and/or three-phase, 50 Hertz appliances running at 400VAC. Both single and three phase sides of the generator may be run at the same time.

CAUTION: Do not exceed the power output of the generator. Damage

to tools or generator will occur. See Technical Data.

Check the nameplate or label provided on tools and appliances to make sure their power requirements are met by the power output of the generator. If the wattage is not given for a particular tool or appliance, contact the tool manufacturer for wattage requirements.

Some appliances and tools require a surge of current when starting. This means that the amount of power needed to initially start the equipment is larger than the power required to keep it running. The generator must be capable of supplying this "surge" current. Other types of appliances require more power than is actually stated on their nameplate.

The information in “Approximate Starting Power Requirements” is offered only as a general guideline to help you determine power requirements for different types of equipment. Check with your nearest Wacker dealer, or contact the manufacturer or dealer of the tool or appliance, if you have questions regarding power requirements.

CAUTION: DO NOT exceed the rated current limit of any receptacle.

CAUTION: If a tool or appliance does not reach full speed within a few

seconds after it is switched on, turn it off immediately to avoid damage.

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GV 7000A/7003A Operation

Approximate Starting Power Requirements

• Incandescent lights and appliances such as irons and hot plates, which use a resistive-type heating element, require the same wattage to start and run as is stated on their nameplates.

• Fluorescent and mercury lamps require 1.2–2 times their stated wattage to start.

• Electrical motors and many types of electrical tools often require a large starting current. The amount of starting current depends on the type of motor and its use.

• Most electrical tools require 1.2–3 times their stated wattage for starting.

• Loads such as submersible pumps and air compressors require a very large force to start. They need as much as 3–5 times the wattage stated on the nameplate in order to start.

If the wattage is not given for a particular tool or appliance, it can be calculated by multiplying its voltage and amperage requirements:

Single Phase: VOLTS x AMPS = WATTS

Three Phase: VOLTS x AMPS x 1.732 x 0.8 = WATTS

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Operation GV 7000A/7003A

4.2 Outdoor Installation

Place the generator in an area where it will not be exposed to rain, snow, or direct sunlight. Make sure it is positioned on firm, level ground, so it will not slide or shift. Position the engine exhaust away from areas where people may be present.

If operating the generator inside a tunnel or deep trench, make sure there is adequate ventilation. Precautions similar to those required when operating indoors may be necessary.

The surrounding area must be free from water and moisture. All components must be protected from excessive moisture.

4.3 Indoor Installation

DANGER

If the generator must be installed indoors, adequate ventilation or exhaust hoses must be provided. When venting exhaust fumes, make sure the exhaust piping is large enough to prevent excessive back pressure to the engine. Back pressure reduces engine efficiency and may cause the engine to overheat.

Exhaust gas from the engine contains poisonous carbon monoxide gas; exposure to carbon monoxide can cause loss of consciousness and may lead to death. Never run the generator indoors or in an enclosed area unless adequate ventilation, through such items as exhaust hoses or fans, is provided.

When installed indoors, steps to prevent fire and explosion such as providing a good, earthen ground, removing all flammable materials near the generator, and using only electrical cables in good condition,

must be observed. See Operating Safety.

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GV 7000A/7003A Operation

4.4 Generator Derating

All generators are subject to derating for altitude and temperature. Internal combustion engines, unless modified, run less efficiently at higher altitudes due to the reduction of air pressure. This translates into a lack of power and thus reduction in generator output. Temperature affects both engine and generator performance. As temperature increases, an engine will run less efficiently and more resistance will be found in electrical components. Therefore, as the temperature increases, the output of the generator decreases. Altitude also affects the cooling capacity of air—the higher the altitude the less dense the air is and thus the lower its ability to transfer heat.

For every increase in altitude of 500 m (1650 ft.) above 1000 m (3300 ft.), the output of the generator will be reduced by 3%. For every increase of 5° C (9° F) in ambient temperature above 40° C (104° F), the output of the generator will be reduced by 3%. Use the tables shown for altitude and temperature deration factors. It may be necessary to consider both altitude and ambient temperature deration factors to determine true generator output.

Ambient Temp.

°C (°F)

45 (113) 3 % 0.97

50 (122) 6 % 0.94

55 (131) 9 % 0.91

60 (140) 12 % 0.88

Altitude

m (ft.)

1500 (4900) 3 % 0.97

2000 (6600) 6 % 0.94

2500 (8200) 9 % 0.91

3000 (9900) 12 % 0.88

3500 (11500) 15 % 0.85

Derate Factor

4000 (13100) 18 % 0.82

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Operation GV 7000A/7003A

4.5 Use of Extension Cords

When a long extension cord is used to connect an appliance or tool to the generator, a voltage loss occurs—the longer the cord, the greater the voltage loss. This results in less voltage being supplied to the appliance or tool and increases the amount of current draw or reduces performance. A cord with a larger cross section will reduce the voltage loss.

CAUTION: Operating equipment at low voltage can cause it to overheat.

Use only tough rubber-sheathed cable in accordance with IEC 245-4.

Damaged cords can cause electric shock. Electric shock can cause serious injury or death. DO NOT use worn, bare, or frayed cords. Replace damaged cords immediately.

WARNING

Do not exceed the rating of the cord.

Contact the cord manufacturer if in doubt about cord use.

Choose the cord size from the Minimum Extension Cord Size Table or calculate minimum cord size using the Minimum Extension Cord Size Graph. The X axis of the graph represents A x m (Ampere x meter)

values. The Y axis represents wire size in mm2. Multiply the operating current for the load in amps (A) by the desired extension cord length in meters (m). Find the result along the X axis. Move up the graph until you reach the appropriate sloped line for your application. Move to the Y axis; this is the recommended minimum cord size.

Example:

For a 3-phase, 400V application, if the operating current for the load is 15 A, and the desired extension cord length is 100 m, then:

15 A x 100 m = 1500 A x m.

1500 A x m = 2.5 mm

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GV 7000A/7003A Operation

Minimum Extension Cord Size Chart

Minimum Extension Cord Size

230V/1~/50Hz 400V/3~/50Hz

Length m Length m

Amp

25 50 100 200 25 50 100 200

Rating

Cross sectional area of wire in mm

2 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

4 1.5 1.5 1.5 2.5 1.5 1.5 1.5 1.5

6 1.5 1.5 1.5 4 1.5 1.5 1.5 2.5

8 1.5 1.5 2.5 6 1.5 1.5 1.5 2.5

10 1.5 1.5 4 6 1.5 1.5 1.5 4

15 1.5 2.5 4 10 1.5 1.5 2.5 6

20 1.5 4 6 16 1.5 1.5 4 6

30 2.5 4 10 25 1.5 2.5 6 10

40 4 6 16 --- 1.5 4 6 ---

Minimum Extension Cord Size Graph

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2.5

1.5

1000

2000

A x m

3000 4000 5000

6000

wc_gr001081

Page 22

Operation GV 7000A/7003A

4.6 Grounding the Generator

The neutral of this machine is not connected to ground. Under standard operating conditions, do not connect the frame PE stud to earth ground. Refer to local codes if machine is used to power a

CAUTION

building or similar distribution system.

4.7 Operating Heavy Loads

Limit operations requiring the maximum rated output of the generator to 20–30 minutes. For continuous operation, do not exceed the continuous rated output of the generator. Refer to the Generator Technical Data specification chart.

wc_gr001286

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GV 7000A/7003A Operation

4.8 Control Panel

See graphic: wc_gr001275 and wc_gr001369

The circuit breaker protects the generator from severe overloads or short circuits. If the circuit breaker opens, turn the engine off immediately and determine the cause before restarting. Check the appliances and tools attached to the generator for defects and make sure their power requirements do not exceed the power rating of the generator or the current limit of the receptacles.

Note: Enlargements of receptacles show protective covers removed for identification purposes only. Never remove protective covers.

GV 7000A

Ref. Description Ref. Description

wc_gr001275

a Main circuit breaker - 22 A b Main circuit breaker - 12 A

c CEE receptacle IP44

230 V, 32 A

d1 Schuko IP44 (CEE 7) receptacle

230 V, 16 A

d3 Swiss receptacle

230 V, 16 A

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d2 CEE receptacle IP44 2P+E

230 V, 16 A

d4 French receptacle

230 V, 16 A

Page 24

Operation GV 7000A/7003A

GV 7003A

Ref. Description Ref. Description

e Main circuit breaker -

10 A, 12 A, 10 A 3-Pole

f1 Schuko IP54 (CEE 7) receptacle

230V, 16 Amp

f3 Swiss receptacle

230 V, 16 A

g1 CEE receptacle IP44 3P+N+E

400 V, 3 Ø, 16 A

f2 CEE receptacle IP44 2P+E

230 V, 16 A

f4 French receptacle

230 V, 16 A

g2 Swiss receptacle

400 V, 3 Ø, 16 A

wc_gr001370

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GV 7000A/7003A Operation

4.9 Before Starting

4.9.1 Read and understand safety and operating instructions at beginning of this manual.

4.9.2 Read and understand the meanings of all warning and operating labels.

4.9.3 Check:

• oil level in engine.

• fuel level.

• condition of air cleaner.

• tightness of external fasteners.

• condition of fuel lines.

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Operation GV 7000A/7003A

4.10 To Start

See Graphic: wc_gr001299

4.10.1 Disconnect all loads from the generator and place main circuit breaker in open position (e2) (GV 5003A, GV 7003A).

4.10.2 Open fuel valve (a).

Note: If engine is cold, move choke (b) to closed position—pull out.. If engine is hot, set choke to open position—push in.

4.10.3 Turn engine switch to "ON" (c1) and pull starter rope (d).

Note: If the oil level in the engine is low, the engine will not start. If this

happens, check oil level and add oil as needed.

4.10.4 Open choke as engine warms (b).

4.10.5 Place main circuit breaker in closed position (e1) (GV 5003A, GV 7003A). Allow the engine to warm up for a few minutes before attaching loads.

4.11 To Stop

See Graphic: wc_gr001299

4.11.1 Turn off and disconnect all tools and appliances attached to the

4.11.2 Turn engine switch to “OFF” (c2).

generator.

wc_gr001299

4.11.3 Close fuel valve (a).

Note: To stop engine quickly in an emergency, turn engine switch to “OFF” (c2).

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GV 7000A/7003A Maintenance

5. Maintenance

5.1 Engine Maintenance

The chart below lists basic machine and engine maintenance. Refer to the engine manufacturer’s Operator’s Manual for additional information on engine maintenance.

5.2 Periodic Maintenance Schedule

Check fuel level.

Check engine oil level.

Inspect air filter. Replace as needed.*

Check external hardware.

Clean air cleaner element.*

Inspect shockmounts for damage.

Change engine oil.*

Check and clean spark plug.

Check and adjust valve clearance.

Clean fuel tank.*

Check condition of fuel line. Replace when necessary.

Daily

before

starting



After

first

20 hrs.



Every

hrs.



Every

100

hrs.



Every

300

hrs.



*Service more frequently in dusty conditions.

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Maintenance GV 7000A/7003A

5.3 Engine Oil

See Graphic: wc_gr000022

5.3.1 Drain the oil while the engine is still warm.

5.3.2 Remove the oil filler plug (a) and the drain plug (b) to drain the oil.

Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off. Dispose of this liquid in accordance with environmental protection legislation.

5.3.3 Install the drain plug.

5.3.4 Fill the engine crankcase with the recommended oil up to the level of

the plug opening (c). See Technical Data for oil quantity and type.

5.3.5 Install the oil filler plug.

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Page 29

GV 7000A/7003A Maintenance

5.4 Air Cleaner

See Graphic: wc_gr0001287

The engine is equipped with a single element air cleaner. Service air cleaner frequently to prevent carburetor malfunction.

CAUTION: NEVER run the engine without the air cleaner. Severe engine damage will occur.

NEVER use gasoline or other types of low flashpoint solvents for cleaning the air cleaner. A fire or explosion could result.

WARNING

To service:

5.4.1 Release latches (a) on the top and bottom of the air cleaner cover (b), and remove the cover.

5.4.2 Check the filter element (c) to be sure it is in good condition. Replace damaged filters.

5.4.3 Wash filter element in solution of mild detergent and warm water. Rinse thoroughly in clean water. Allow element to dry thoroughly. Soak element in clean engine oil and squeeze out excess oil.

5.4.4 Reinstall the element and air cleaner cover.

wc_gr001287

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Maintenance GV 7000A/7003A

5.5 Spark Plug

See Graphic: wc_gr000028

Clean or replace the spark plug as needed to ensure proper operation. Refer to the engine owner’s manual.

The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot.

WARNING

Note: Refer to the Technical Data for the recommended spark plug type and the electrode gap setting.

5.5.1 Remove the spark plug and inspect it.

5.5.2 Replace the spark plug if the insulator is cracked or chipped.

5.5.3 Clean the spark plug electrodes with a wire brush.

5.5.4 Set the electrode gap (a).

5.5.5 Tighten the spark plug securely.

CAUTION: A loose spark plug can become very hot and may cause engine damage.

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GV 7000A/7003A Maintenance

5.6 Engine Speed

See Graphic: wc_gr001300

Generators require a fixed engine speed to maintain the correct voltage. Engine speed is controlled by a governor which automatically adjusts to varying loads on the engine to maintain a constant speed of 3000 rpm. There is no throttle control.

To set the engine to the proper speed:

Turn the speed adjusting screw (a) in or out to obtain a no-load speed of 3100 rpm.

CAUTION: Setting the engine speed too high or too low may damage tools and other appliances attached to the generator.

Adjust engine to the no load or idle speed per the Technical Data.

5.6.1 Start the engine and allow it to warm up to normal operating temperature.

5.6.2 Turn the throttle stop screw (a) in to increase speed, out to decrease speed. Make sure the throttle lever is touching the stop screw before measuring rpm.

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wc_gr001300

Page 32

Maintenance GV 7000A/7003A

5.7 Storage

Before storing the generator for a long period of time:

5.7.1 Close the fuel valve and remove and empty the sediment cup or fuel strainer.

5.7.2 Disconnect the fuel line from the carburetor. Place open end of fuel line into a suitable container and open fuel valve to drain fuel from tank.

Gasoline is extremely flammable. Drain the fuel tank in a wellventilated area. DO NOT drain the fuel tank in an area with flames or

WARNING

5.7.3 Loosen the drain screw on the carburetor and drain any remaining fuel

5.7.4 Change the engine oil.

5.7.5 Remove the spark plug and pour approximately 30 ml (1 ounce) of

sparks.

from the carburetor.

clean engine oil into the cylinder. Crank the engine a few turns to distribute the oil to the inside of the cylinder walls.

5.7.6 Pull the starter rope slowly until resistance is felt and leave the handle in this position. This ensures that the intake and exhaust valves are closed.

5.7.7 Store the generator in a clean, dry area.

5.8 Transport

Let the engine cool before transporting the generator or storing indoors, to avoid burns or fire hazards.

WARNING

When transporting the generator:

5.8.1 Turn the engine fuel valve to the OFF position.

5.8.2 Position the generator level to prevent fuel from spilling.

5.8.3 Secure the generator by tying it down with a suitable rope.

When transporting the machine by hand, be sure to employ manpower commensurate with the weight of the machine. To avoid back injury

WARNING

when lifting the machine, bend the knees to pick it up rather than bending your back only.

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GV 7000A/7003A Maintenance

5.9 Troubleshooting

Problem / Symptom Reason / Remedy

If engine doesn't start, check

that:

If engine starts but there is no power at receptacles, check that:

If engine starts but runs erratically, check:

• Engine switch is on "Start".

• Fuel valve is open.

• Fuel tank has fuel.

• Choke lever is in correct position. Choke should be closed when starting a cold engine.

• All loads are disconnected from generator.

• Spark plug is in good condition.

• Spark plug cap is tight.

• Engine oil level is adequate.

• Circuit breaker is closed.

• Wiring from generator to receptacles is tight.

• Condition of air filter.

• Condition of spark plug and plug cap.

• Freshness of fuel.

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Maintenance GV 7000A/7003A

5.10 Electrical Schematic—GV 7000A

See Graphic: wc_gr001302

G/Y

GV 7000A

Ref. Description Ref. Description

G/Y

wc_gr001302

1 Main Windings 6 Surge Absorber

2 Auxiliary Winding 7 Circuit Breaker

3 Capacitor 8 Receptacle

230 V, 1 Ø, 16 A

4 Rotor Windings 9 Receptacle

230 V, 1 Ø, 32 A

5 Diode

Wire Colors

B Black V Violet Or Orange

G Green W White Pr Purple

L Blue Y Yellow Sh Shield

P Pink Br Brown LL Light Blue

R Red Cl Clear G/Y Green/Yellow

TTan GrGray

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GV 7000A/7003A Maintenance

5.11 Electrical Schematic—GV 7003A

See Graphic: wc_gr001249

ROTOR

GV 5003A GV 7003A

W1 V2

3~400V/16A

G/Y

GND

1~230V/16A

wc_gr001249

Ref. Description Ref. Description

1 Main Windings 6 Terminal board

2 Auxiliary Winding 7 Circuit Breaker

3 Regulator (Rectifier) 8 Receptacle

230 V, 1 Ø, 16 A

4 Rotor Windings 9 Receptacle

400 V, 3 Ø, 16 A

5 Compound (transformer) 10 Brushes

Wire Colors

B Black V Violet Or Orange

G Green W White Pr Purple

L Blue Y Yellow Sh Shield

P Pink Br Brown LL Light Blue

R Red Cl Clear G/Y Green/Yellow

T Tan Gr Gray

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Maintenance GV 7000A/7003A

Notes

wc_tx000274gb.fm 34

Page 37

EC DECLARATION OF CONFORMITY

CE-KONFORMITÄTSERKLÄRUNG

DECLARACIÓN DE CONFORMIDAD DE LA CE

DÉCLARATION DE CONFORMITÉ C.E.

WACKER CORPORATION, N92 W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA

AUTHORIZED REPRESENTATIVE IN THE EUROPEAN UNION BEVOLLMÄCHTIGTER VERTRETER FÜR DIE EUROPÄISCHE GEMEINSCHAFT REPRESENTANTE AUTORIZADO EN LA UNIÓN EUROPEA REPRÉSENTANT AGRÉÉ AUPRÈS DE L’UNION EUROPÉENNE

hereby certifies that the construction equipment specified hereunder / bescheinigt, daß das Baugerät / certifica que la máquina de construcción / atteste que le matériel :

1. Category / Art / Categoría / Catégorie

WACKER CONSTRUCTION EQUIPMENT AG Preußenstraße 41 80809 München

Power Generators

Kraftstromerzeuger

Grupos Electrógenos

Groupe Électrogènes de Puissance

2. Type - Typ - Tipo - Type

GV 7000A

3. Item number of equipment / Artikelnummer / Número de referencia de la máquina / Numéro de référence du matériel :

0009348, 0009353, 0009358, 0009363

4. Electric power / Elektrische Leistung / Potencia eléctrica / Force motrice :

4,95 kW

Has been sound tested per Directive 2000/14/EC / In Übereinstimmung mit Richtlinie 2000/14/EG bewertet worden ist / Ha sido ensayado en conformidad con la norma 2000/14/CE / A été mis à l’épreuve conforme aux dispositions de la directive 2000/14/CEE :

Conformity Assessment Procedure / Konformitätsbewertungsverfahren / Procedimiento para ensayar conformidad / Procédé pour l’épreuve de conformité

Annex VIII / Anhang VIII Anexo VIII / Annexe VIII

and has been produced in accordance with the following standards: und in Übereinstimmung mit folgenden Richtlinien hergestellt worden ist: y ha sido fabricado en conformidad con las siguientes normas: et a été produit conforme aux dispositions des directives européennes ci-après :

Name and address of notified body / Bei folgender einbezogener Prüfstelle / Oficina matriculadora / Organisme agrée

Société Nationale de

Certification et

Homologation L-5201

Sandweiler# 0499

Measured sound power level / Gemessener Schallleistungspegel / Nivel de potencia acústica determinado / Niveau de puissance acoustique fixé

97 dB(A) 97 dB(A)

Guaranteed sound power level / Garantierter Schallleistungs-pegel / Nivel de potencia acústica garantizado / Niveau de puissance acoustique garanti

2000/14/EC 2002/88/EC 89/336/EEC 98/37/EEC

14.02.06

Date / Datum / Fecha / Date

2006_Value_Gen_GV7000A_Q.fm

William Lahner Dan Domanski Vice President of Engineering Manager, Product Engineering

WACKER CORPORATION

Page 38

Page 39

EC DECLARATION OF CONFORMITY

CE-KONFORMITÄTSERKLÄRUNG

DECLARACIÓN DE CONFORMIDAD DE LA CE

DÉCLARATION DE CONFORMITÉ C.E.

WACKER CORPORATION, N92 W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA

hereby certifies that the construction equipment specified hereunder / bescheinigt, daß das Baugerät / certifica que la máquina de construcción / atteste que le matériel :

1. Category / Art / Categoría / Catégorie

WACKER CONSTRUCTION EQUIPMENT AG Preußenstraße 41 80809 München

Power Generators

Kraftstromerzeuger

Grupos Electrógenos

Groupe Électrogènes de Puissance

2. Type - Typ - Tipo - Type

GV 7003A

3. Item number of equipment / Artikelnummer / Número de referencia de la máquina / Numéro de référence du matériel :

0009349, 0009354, 0009359, 0009364

4. Electric power / Elektrische Leistung / Potencia eléctrica / Force motrice :

5,68 kW

Conformity Assessment Procedure / Konformitätsbewertungsverfahren / Procedimiento para ensayar conformidad / Procédé pour l’épreuve de conformité

Annex VIII / Anhang VIII Anexo VIII / Annexe VIII

Name and address of notified body / Bei folgender einbezogener Prüfstelle / Oficina matriculadora / Organisme agrée

Société Nationale de

Certification et

Homologation L-5201

Sandweiler# 0499

Measured sound power level / Gemessener Schallleistungspegel / Nivel de potencia acústica determinado / Niveau de puissance acoustique fixé

97 dB(A) 97 dB(A)

Guaranteed sound power level / Garantierter Schallleistungs-pegel / Nivel de potencia acústica garantizado / Niveau de puissance acoustique garanti

2000/14/EC 2002/88/EC 89/336/EEC 98/37/EEC

14.02.06

Date / Datum / Fecha / Date

2006_Value_Gen_GV7003A_Q.fm

William Lahner Dan Domanski Vice President of Engineering Manager, Product Engineering

WACKER CORPORATION

Page 40

Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-3 54 02 - 0 · Fax: +49 - (0)89-3 54 02-3 90 Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (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 60 32 · Fax: +852 2406 60 21