Operator´s manual
Portable Generator
GV 7000A
GV 7003A
02.2013
5100004230en / 002
Manufacturer
Wacker Neuson Produktion GmbH & Co. KG
Preußenstraße 41
80809 München
www.wackerneuson.com
Tel.: +49-(0)89-354 02-0
Fax: +49-(0)89-354 02-390
Translation of the original operator's manual in German
1 Foreword
1
Foreword
This operator's manual contains information and procedures for the safe operation and maintenance of your Wacker Neuson 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 Neuson 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
Neuson machine in accordance with the instructions in this operator's manual.
Your reward will be troublefree operation and a high degree of availability.
Defective machine parts must be replaced immediately!
Please contact your Wacker Neuson representative if you have any questions
concerning operation or maintenance.
All rights reserved, especially reproduction and distribution rights.
Copyright 2013 Wacker Neuson Produktion GmbH & Co. KG
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 Neuson.
Any type of reproduction, distribution or storage on data media of any type and
form not authorized by Wacker Neuson 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.
3
100_0000_0002.fm
2 Introduction
2
2.1
Introduction
Means of representation for this operator's manual
Warning symbols
This operator's manual contains safety information of the categories:
DANGER, WARNING, CAUTION, NOTICE.
They should be followed to prevent danger to life and limb of the operator or damage to equipment and exclude improper service.
DANGER
This warning notice indicates immediate hazards that result in serious injury or
even death.
X Danger can be avoided by the following the actions mentioned.
WARNING
This warning notice indicates possible hazards that can result in serious injury
or even death.
X Danger can be avoided by the following the actions mentioned.
CAUTION
This warning notice indicates possible hazards that can result in minor injury.
X Danger can be avoided by the following the actions mentioned.
NOTICE
This warning notice indicates possible hazards that can result in material damage.
X Danger can be avoided by the following the actions mentioned.
Notes
Note: Complementary information will be displayed here.
100_0000_0003.fm
4
2 Introduction
Instructions
X
This symbol indicates there is something for you to do.
1. Numbered instructions indicate that you have to carry out something in a defined sequence.
„
2.2
This symbol is used for lists.
Wacker Neuson representative
Depending on your country, your Wacker Neuson representative is your Wacker
Neuson service, your Wacker Neuson affiliate or your Wacker Neuson dealer.
You can find the addresses in the Internet at www.wackerneuson.com.
The address of the manufacturer is located at the beginning of this operator's
manual.
2.3
Described machine types
This operator's manual is valid for different machine types from a product range.
Therefore some figures can differ from the actual appearance of your machine.
It is also possible that the descriptions include components which are not a part
of your machine.
Details for the described machine types can be found in the chapter Technical
data.
5
100_0000_0003.fm
2 Introduction
2.4
Identification of the machine
Nameplate data
The nameplate lists information that uniquely identifies your machine. This information is needed to order spare parts and when requesting additional technical
information.
X
Enter the information of your machine into the following table:
Item
100_0000_0003.fm
Designation
Your information
1
Group and type
2
Construction year
3
Machine no.
4
Version no.
5
Item no.
6
EG-Konformitätserklärung
Hersteller
Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München
Produkt
Produkt
GV 7000A
Produkt-Art
Generator
Produkt-Funktion
Erzeugen von Strom
Artikel-Nummer
0009348
Installierte Nutzleistung
GV 7003A
0009353
5,47 kW
5100002155
5,60 kW
Gemessener
Schallleistungspegel
97 dB(A)
Garantierter
Schallleistungspegel
97 dB(A)
Konformitätsbewertungsverfahren
Nach 2000/14/EG, Anhang VIII.
Benannte Stelle
SNCH Société Nationale de Certification et ’Homologation, L-5230 Sandweiler
Richtlinien und Normen
Hiermit erklären wir, dass dieses Produkt den einschlägigen Bestimmungen und
Anforderungen folgender Richtlinien und Normen entspricht:
2006/42/EG, 2006/95/EG, 2000/14/EG, 2004/108/EG, 2011/65/EU
Bevollmächtigter für technische Unterlagen
Axel Häret,
Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München
München, 01.02.2013
Dr. Michael Fischer
Geschäftsführer Technik und Innovation
Original-Konformitätserklärung
GV 7000A / 7003A
Table of Contents
Foreword
1
3
Safety Information
1.1
1.2
1.3
1.4
1.5
11
Signal Words Used in this Manual ..................................................... 11
Machine Description and Intended Use ............................................. 12
Safety Guidelines for Operating the Machine ..................................... 13
Operator Safety while Using Internal Combustion Engines ............... 16
Service Safety .................................................................................... 17
2
Labels
19
3
Lifting and Transporting
20
4
Operation
21
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
Preparing the Machine for First Use ................................................... 21
Power Requirements .......................................................................... 22
Installation .......................................................................................... 22
Generator Derating ............................................................................. 24
Grounding the Generator ................................................................... 25
Operating Heavy Loads ...................................................................... 25
Use of Extension Cords ...................................................................... 26
Control Panel ...................................................................................... 28
Before Starting ................................................................................... 30
Starting ............................................................................................... 30
Stopping ............................................................................................. 31
Emergency Shutdown Procedure ....................................................... 31
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9
Table of Contents
5
GV 7000A / 7003A
Maintenance
5.1
5.2
5.3
5.4
5.5
5.6
32
Periodic Maintenance Schedule ..........................................................32
Engine Oil ............................................................................................33
Servicing the Air Cleaner .....................................................................34
Spark Plug ...........................................................................................35
Engine Speed ......................................................................................36
Long-Term Storage .............................................................................37
6
Basic Troubleshooting
38
7
Technical Data
39
8
Schematics
42
8.1
8.2
GV 7000A—Electrical Schematic ........................................................42
GV 7003A—Electrical Schematic ........................................................43
10
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GV 7000A / 7003A
1
1.1
Safety Information
Safety Information
Signal Words Used in this Manual
This manual contains DANGER, WARNING, CAUTION, NOTICE, and
NOTE signal words 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 hazards.
f Obey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
f To avoid death or serious injury from this type of hazard, obey all safety messages that
follow this signal word.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
f To avoid possible death or serious injury from this type of hazard, obey all safety messages that follow this signal word.
CAUTION!
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
f To avoid possible minor or moderate injury from this type of hazard, obey all safety messages that follow this signal word.
NOTICE: Used without the safety alert symbol, NOTICE indicates a
situation which, if not avoided, could result in property damage.
Note: A Note contains additional information important to a procedure.
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11
Safety Information
1.2
GV 7000A / 7003A
Machine Description and Intended Use
This machine is a portable electric power source. The Wacker
Neuson Portable Generator consists of a tubular steel frame
surrounding a fuel tank, a gasoline engine, a control panel, and an
electric alternator. The control panel includes controls and
receptacles. As the engine runs, the generator converts mechanical
energy into electric power. The operator connects loads to the electric
power receptacles.
This machine is intended for the purpose of supplying electrical power
to connected loads. Refer to the product specifications for the output
voltage and frequency of this generator, and the maximum output
power limit of this generator.
This machine has been designed and built strictly for the intended use
described above. Using the machine for any other purpose could
permanently damage the machine or seriously injure the operator or
other persons in the area. Machine damage caused by misuse is not
covered under warranty.
The following are some examples of misuse:
•
Connecting a load that has voltage and frequency requirements
that are incompatible with the generator output
•
Overloading the generator with a load that draws excessive
power during either continuous running or start-up
•
Operating the generator in a manner that is inconsistent with all
federal, state and local codes and regulations
•
Using the machine as a ladder, support, or work surface
•
Using the machine to carry or transport passengers or equipment
•
Operating the machine outside of factory specifications
•
Operating the machine in a manner inconsistent with all warnings
found on the machine and in the Operator’s Manual
This machine has been designed and built in accordance with the
latest global safety standards. It has been carefully engineered to
eliminate hazards as far as practicable and to increase operator
safety through protective guards and labeling. However, some risks
may remain even after protective measures have been taken. They
are called residual risks. On this machine, they may include exposure
to:
•
Heat, noise, exhaust, and carbon monoxide from the engine
•
Fire hazards from improper refueling techniques
•
Fuel and its fumes
•
Electric shock and arc flash
12
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GV 7000A / 7003A
•
Safety Information
Personal injury from improper lifting techniques
To protect yourself and others, make sure you thoroughly read and
understand the safety information presented in this manual before
operating the machine.
1.3
Safety Guidelines for Operating the Machine
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.
f 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.
f ONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
f 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.
f 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.
WARNING
Electrocution, fire, or explosion hazards. 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, serious injury, or death to utility workers!
f Comply with the connection requirements described below.
Connection requirements
The following are required when connecting the generator to a
building’s electrical system.
wc_si000530gb.fm
•
The generator must meet the power, voltage, and frequency
requirements of the equipment in the building.
•
The generator power must be isolated from the utility power.
•
Connections from the generator to a building’s electrical system
must be made by a qualified electrician.
•
Electrical connections must comply with all applicable laws and
electrical codes.
13
Safety Information
WARNING
GV 7000A / 7003A
Familiarity and proper training are required for the safe operation of the
machine. Machines operated improperly or by untrained personnel
can be hazardous. Read the operating instructions contained in 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 machine before
being allowed to operate it.
Operator qualifications
Only trained personnel are permitted to start, operate, and shut down
the machine. They also must meet the following qualifications:
•
have received instruction on how to properly use the machine
•
are familiar with required safety devices
The machine must not be accessed or operated by:
•
children
•
people impaired by alcohol or drugs
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while
operating this machine:
•
Close-fitting work clothes that do not hinder movement
•
Safety glasses with side shields
•
Hearing protection
•
Safety-toed footwear
1.3.1
NEVER operate the generator when open containers of fuel, paint, or
other flammable liquids are near.
1.3.2
NEVER operate the generator, or tools attached to the generator, with
wet hands.
1.3.3
NEVER use worn electrical cords. Severe electrical shock and
equipment damage may result.
1.3.4
NEVER run the electrical cords under the generator, or over vibrating
or hot parts.
1.3.5
NEVER enclose or cover the generator when it is in use or when it is
hot.
1.3.6
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.
1.3.7
NEVER operate the machine in snow, rain, or standing water.
1.3.8
NEVER allow untrained personnel to operate or service the generator.
The generator set should be set up by a certified electrician.
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Safety Information
1.3.9
Store the machine properly when it is not being used. The machine
should be stored in a clean, dry location out of the reach of children.
1.3.10
Be sure the machine is on a firm, level surface and will not tip, roll,
slide, or fall while operating.
1.3.11
ALWAYS transport the generator in an upright position.
1.3.12
ALWAYS keep the machine at least one meter (three feet) away from
structures, buildings, and other equipment during use.
1.3.13
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.
1.3.14
ALWAYS remove all tools, cords, and other loose items from the
generator before starting it.
1.3.15
DO NOT ground this generator.
Generator vibration
Generators vibrate in normal use. During and after the use of the
generator, inspect the generator as well as extension cords and
power supply cords connected to it for damage from vibration.
wc_si000530gb.fm
•
Have damaged items repaired or replaced as necessary.
•
Do not use plugs or or cords that show signs of damage such as
broken or cracked insulation or damaged blades.
15
Safety Information
1.4
GV 7000A / 7003A
Operator Safety while Using Internal Combustion Engines
WARNING
Internal combustion engines present special hazards during operation and fueling.
Failure to follow the warnings and safety standards could result in severe injury or
death.
f Read and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
f 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.
Refueling safety
When refueling the engine:
•
Do not smoke.
•
Do not refuel if the generator is sitting in a truck fitted with a
plastic bed liner. Static electricity can ignite the fuel or fuel vapors.
•
Do not refuel a hot or running engine.
•
Do not refuel the engine near an open flame.
When refueling the engine, always:
•
Refill the fuel tank in a well-ventilated area.
•
Replace the fuel tank cap after refueling.
Operating safety
When operating the generator:
•
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.
•
Do not run the engine near open flames.
•
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.
•
Do not smoke while operating the machine.
16
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1.5
Safety Information
Service Safety
WARNING
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
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.
Personal Protective Equipment (PPE)
Wear the following Personal Protective Equipment (PPE) while
servicing or maintaining this machine:
•
Close-fitting work clothes that do not hinder movement
•
Safety glasses with side shields
•
Hearing protection
•
Safety-toed footwear
In addition, before servicing or maintaining the machine:
wc_si000530gb.fm
•
Tie back long hair.
•
Remove all jewelry (including rings).
1.5.1
Do not use gasoline or other types of fuels or flammable solvents to
clean parts, especially in enclosed areas. Fumes from fuels and
solvents can become explosive.
1.5.2
DO NOT attempt to clean or service the machine while it is running.
1.5.3
Do not modify the machine without the express written approval of the
manufacturer.
1.5.4
DO NOT allow water to accumulate around the base of the machine.
If water is present, move the machine and allow the machine to dry
before servicing.
1.5.5
DO NOT service the machine if your clothing or skin is wet.
1.5.6
DO NOT allow untrained personnel to service this equipment. Only
trained electrical technicians should be allowed to service the electrical
components of this equipment.
1.5.7
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.
1.5.8
ALWAYS replace the safety devices and guards after repairs and
maintenance.
1.5.9
ALWAYS let the engine cool before transporting or servicing the
machine.
1.5.10
ALWAYS keep hands, feet, and loose clothing away from the moving
parts on the generator and engine.
17
Safety Information
GV 7000A / 7003A
1.5.11 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.
1.5.12 ALWAYS keep the fuel lines in good condition and properly connected.
Leaking fuel and fumes are extremely explosive.
1.5.13 When replacement parts are required for this machine, use only
Wacker Neuson replacement parts or those parts equivalent to the
original in all types of specifications, such as physical dimensions,
type, strength, and material.
18
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2 Safety and information labels
2
Safety and information labels
Your machine has adhesive labels containing the most important instructions
and safety information.
„
„
Make sure that all the labels are kept legible.
Replace any missing or illegible labels.
The item numbers for the labels are in the parts book.
Item
100_0402_ls_0004.fm
Label
Description
1
Guaranteed sound power level.
2
DANGER!
Asphyxiation hazard.
„ Engines emit carbon monoxide.
„ Do not run the machine indoors or in
an enclosed area.
„ NEVER use inside a home or garage,
„ EVEN IF doors and windows are open.
Only use OUTSIDE and far away from
windows, doors, and vents.
„ Read the Operator’s Manual.
„ No sparks, flames, or burning objects
near the machine.
„ Stop the engine before refueling.
3
Warning of hot surface.
4
Warning of hot surface.
Potential Earth - Connect cable from
grounding rod to this point.
WARNING!
Electric shock can cause serious injury or
death.
19
Lifting and Transporting
3
GV 7000A / 7003A
Lifting and Transporting
Lifting the Machine
This generator, while compact, is heavy enough to cause injury if
proper lifting techniques are not used. Observe the following
guidelines when lifting the generator.
•
Do not attempt to lift and carry the generator unassisted. Use
appropriate lifting equipment such as slings, chains, hooks,
ramps, or jacks.
•
Make sure lifting equipment is attached securely and has enough
weight-bearing capacity to lift or hold the generator safely.
•
Remain aware of the location of other people nearby when lifting
the generator.
Transporting the Machine
Observe the following guidelines when transporting the generator to
and from the job site.
•
Allow the engine to cool before transporting the generator.
•
Drain the fuel tank.
•
Close the fuel valve.
•
Ensure that the generator is securely strapped down in the
transport vehicle to prevent it from sliding or tipping.
•
Do not refuel the generator in or on the transport vehicle. Move
the generator to its operating location and then fill the fuel tank.
20
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4
4.1
Operation
Operation
Preparing the Machine for First Use
Preparing for first use
To prepare your machine for first use:
4.1.1
Make sure all loose packaging materials have been removed from the
machine.
4.1.2
Check the machine and its components for damage. If there is visible
damage, do not operate the machine! Contact your Wacker Neuson
dealer immediately for assistance.
4.1.3
Take inventory of all items included with the machine and verify that
all loose components and fasteners are accounted for.
4.1.4
Attach component parts not already attached.
4.1.5
Add fluids as needed and applicable, including fuel, engine oil, and
battery acid.
4.1.6
Move the machine to its operating location.
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.
f 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.
f ONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
f 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.
f 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.
Using gasoline / ethanol blends
This portable generator is not for use with gasoline / ethanol blends
with over 15% ethanol.
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21
Operation
4.2
GV 7000A / 7003A
Power Requirements
Wacker Neuson generator Model GV 7000A is designed to operate
single-phase, 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.
NOTICE: 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 Neuson dealer, or contact the manufacturer or dealer of the
tool or appliance, if you have questions regarding power requirements.
NOTICE: DO NOT exceed the rated current limit of any receptacle.
NOTICE: 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.
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.
22
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GV 7000A / 7003A
Operation
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
4.3
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.
The surrounding area must be free from water and moisture. All
components must be protected from excessive moisture.
wc_tx001624gb.fm
23
Operation
4.4
GV 7000A / 7003A
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)
Derate
Factor
45 (113)
3%
0.97
50 (122)
6%
0.94
55 (131)
9%
0.91
60 (140)
12 %
0.88
Altitude
m (ft.)
Derate
Factor
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
4000 (13100)
18 %
0.82
24
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4.5
Operation
Grounding the Generator
CAUTION
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
building or similar distribution system.
wc_gr001286
4.6
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_tx001624gb.fm
25
Operation
4.7
GV 7000A / 7003A
Use of Extension Cords
WARNING
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.
NOTICE: 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.
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 mm2.
26
wc_tx001624gb.fm
GV 7000A / 7003A
Operation
Minimum Extension Cord Size Table
Minimum Extension Cord Size
Amp
Rating
230V/1~/50Hz
400V/3~/50Hz
Length m
Length m
25
50
100
200
25
50
100
200
Cross sectional area of wire in mm2
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
25
z
V 50 H
0
3
2
1~
16
10
mm
2
z
V 50 H
0
0
4
3~
6
4
2.5
1.5
0
1000
2000
3000
Axm
wc_tx001624gb.fm
27
4000
5000
6000
Operation
4.8
GV 7000A / 7003A
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.
d1
d2
d3
d4
c
b
a
GV 7000A
wc_gr001275
Ref.
Description
a
Main circuit breaker - 22 A
c
CEE receptacle IP44
230 V, 32 A
d1
d3
Ref.
Description
b
Main circuit breaker - 12 A
Schuko IP44 (CEE 7) receptacle
230 V, 16 A
d2
CEE receptacle IP44 2P+E
230 V, 16 A
Swiss receptacle
230 V, 16 A
d4
French receptacle
230 V, 16 A
28
wc_tx001624gb.fm
GV 7000A / 7003A
Operation
g1
f2
f1
g2
e
f4
f3
GV 7003A
wc_gr001370
Ref.
Description
e
Main circuit breaker 10 A, 12 A, 10 A 3-Pole
f1
Schuko IP54 (CEE 7) receptacle
230V, 16 Amp
f2
CEE receptacle IP44 2P+E
230 V, 16 A
f3
Swiss receptacle
230 V, 16 A
f4
French receptacle
230 V, 16 A
g1
CEE receptacle IP44 3P+N+E
400 V, 3 Ø, 16 A
g2
Swiss receptacle
400 V, 3 Ø, 16 A
wc_tx001624gb.fm
Ref.
29
Description
Operation
4.9
GV 7000A / 7003A
Before Starting
DANGER
f 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.
4.10
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.
Starting
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.
30
wc_tx001624gb.fm
GV 7000A / 7003A
e2
Operation
b
c2
c1
e1
d
a
wc_gr001299
4.11
Stopping
See Graphic: wc_gr001299
4.11.1
Turn off and disconnect all tools and appliances attached to the
generator.
4.11.2
Turn engine switch to “OFF” (c2).
4.11.3
Close fuel valve (a).
Note: To stop engine quickly in an emergency, turn engine switch to
“OFF” (c2).
4.12
Emergency Shutdown Procedure
Procedure
If a breakdown or accident occurs while the machine is operating,
follow the procedure below:
4.12.1
Stop the engine.
4.12.2 Turn off the fuel supply.
4.12.3 Disconnect tools from the machine.
4.12.4 Allow the machine to cool.
4.12.5 Contact the rental yard or machine owner for further instructions.
wc_tx001624gb.fm
31
Maintenance
5
5.1
GV 7000A / 7003A
Maintenance
Periodic Maintenance Schedule
The table below lists basic machine maintenance. Tasks designated
with check marks may be performed by the operator. Tasks
designated with square bullet points require special training and
equipment.
Daily
before
starting
Check fuel level.
3
Check engine oil level.
3
Inspect air filter. Replace as needed.*
3
Check external hardware.
3
After
first
20 hrs.
Clean air cleaner element.*
Every
50
hrs.
Every
100
hrs.
Every
300
hrs.
3
Inspect shockmounts for damage.
3
Change engine oil.*
„
Check and clean spark plug.
„
„
Check and adjust valve clearance.
„
Clean fuel tank.*
„
Check condition of fuel line. Replace
when necessary.
„
*Service more frequently in dusty conditions.
32
wc_tx001625gb.fm
GV 7000A / 7003A
5.2
Maintenance
Engine Oil
See Graphic: wc_gr000022
5.2.1
Drain the oil while the engine is still warm.
5.2.2
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.
5.2.3
Install the drain plug.
5.2.4
Fill the engine crankcase with the recommended oil up to the level of
the plug opening (c). See section Technical Data for oil quantity and
type.
5.2.5
Install the oil filler plug.
wc_gr000022
wc_tx001625gb.fm
33
Maintenance
5.3
GV 7000A / 7003A
Servicing the Air Cleaner
See Graphic: wc_gr0001287
The engine is equipped with a single element air cleaner. Service air
cleaner frequently to prevent carburetor malfunction.
NOTICE: 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:
5.3.1
Release latches (a) on the top and bottom of the air cleaner cover (b),
and remove the cover.
5.3.2
Check the filter element (c) to be sure it is in good condition. Replace
damaged filters.
5.3.3
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.
5.3.4
Reinstall the element and air cleaner cover.
a
b
c
wc_gr001287
34
wc_tx001625gb.fm
GV 7000A / 7003A
5.4
Maintenance
Spark Plug
See Graphic: wc_gr000028
Clean or replace the spark plug as needed to ensure proper operation.
Refer to your engine operator’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 section “Technical Data” for the recommended spark
plug type and the electrode gap setting.
5.4.1
Remove the spark plug and inspect it.
5.4.2
Replace the spark plug if the insulator is cracked or chipped.
5.4.3
Clean the spark plug electrodes with a wire brush.
5.4.4
Set the electrode gap (a).
5.4.5
Tighten the spark plug securely.
NOTICE: A loose spark plug can become very hot and may cause
engine damage.
wc_tx001625gb.fm
35
Maintenance
5.5
GV 7000A / 7003A
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.
NOTICE: 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.
5.5.1
Start the engine and allow it to warm up to normal operating
temperature.
5.5.2
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.
a
wc_gr001300
36
wc_tx001625gb.fm
GV 7000A / 7003A
5.6
Maintenance
Long-Term Storage
Before storing generator for a long period of time:
5.6.1
Turn the engine fuel valve to the OFF position.
5.6.2
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 fuel tank in a well ventilated
area. DO NOT drain tank in an area with flames or sparks.
WARNING
wc_tx001625gb.fm
5.6.3
Loosen the drain screw on the carburetor and drain any remaining fuel
from carburetor.
5.6.4
Change the engine oil.
5.6.5
Remove the spark plug and pour approximately 30 ml (1 ounce) of
clean engine oil into the cylinder. Crank the engine a few turns to
distribute the oil to the inside of the cylinder walls.
5.6.6
Pull the starter rope slowly until resistance is felt and leave handle in
this position. This ensures that the intake and exhaust valves are
closed.
5.6.7
Store generator in a clean, dry area.
37
Basic Troubleshooting
6
GV 7000A / 7003A
Basic Troubleshooting
Problem / Symptom
Reason / Remedy
If engine doesn't start, check
that:
• 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.
If engine starts but there is no
power at receptacles, check
that:
• Circuit breaker is closed.
If engine starts but runs erratically, check:
• Condition of air filter.
• Wiring from generator to receptacles is tight.
• Condition of spark plug and plug cap.
• Freshness of fuel.
38
wc_tx001618gb.fm
7 Technical data
7
7.1
Technical data
GV 7000
Designation
Unit
Item no.
GV 7000A
GV 7000A
0009348
0009353
Maximum Output (LTP)
kVA
7,2
Continuous Output (COP)
kVA
6,0
Net installed power
kW
5,47
Type
Single voltage, single phase Brushless, capacitor regulator
system
AC Voltages Available
V
230
Phase
~
1
Frequency
Hz
50
Power Factor
cos
0,9
AC receptacles
230V 16A 1~ CEE7/4,
230V 32A 1~ CEE
230V 16A 1~ CEE7/5,
230V 32A 1~ CEE
AC receptacles
qty
2
Main Circuit Breaker
A
25
Length
mm (in)
729 (28.7)
Width
mm (in)
500 (19.7)
Height
mm (in)
536 (21.1)
Weight
kg (lb)
76,0 (167.6)
Sound pressure level LpA *
dB(A)
77,0
Standard
Sound power level LWA
measured
guaranteed
DIN EN ISO 11201
dB(A)
97,0
97,0
Standard
2000/14/EC
* Measured in 4 m away.
100_0402_td_0004.fm
39
7 Technical data
7.2
GV 7003
Designation
Unit
GV 7003A
Item no.
5100002155
Maximum Output (LTP)
kVA
8,3
Continuous Output (COP)
kVA
7,0
Net installed power
kW
5,60
Type
Single voltage, single phase Brushless, capacitor regulator
system
AC Voltages Available
V
230 / 400
Phase
~
1~ + 3~
Frequency
Hz
50
Power Factor
cos
0,8
AC receptacles
230V 16A 1~ CEE, 400V 16A 3~ CEE, 230V 16A 1~ CEE7/4
AC receptacles
qty
3
Main Circuit Breaker
A
25
Length
mm (in)
729 (28.7)
Width
mm (in)
500 (19.7)
Height
mm (in)
536 (21.7)
Weight
kg (lb)
81,0 (198.9)
Sound pressure level LpA *
dB(A)
77,0
Standard
Sound power level LWA
measured
guaranteed
DIN EN ISO 11201
dB(A)
97,0
97,0
Standard
2000/14/EC
* Measured in 4 m away.
40
100_0402_td_0004.fm
7 Technical data
7.3
Combustion engine
Designation
GV 7000A
Manufacturer
GV 7003A
Honda
Engine type
GX390RT2
Combustion method
Four-cycle
Cooling
Air cooling
Cylinder
1
Engine displacement
cm3
(in3)
389
(23.7)
Fuel type
Fuel consumption
Ottokraftstoff
l/h
(gph us)
2.1
(0.6)
Mixture preparation
Tank capacity
Carburetor
l
(gal us)
11,0
(2.9)
Oil specification
SAE 10W-40
Rated output
kW
7.0
Rated speed
rpm
3,600
Standard
Upper idling speed
SAE J1349
rpm
3,000
Type of spark plug
Spark plug air gap
NGK BPR5ES
mm (in)
0.7 (0.027)
Starter type
100_0402_td_0004.fm
Recoil starter
41
Schematics
8
GV 7000A / 7003A
Schematics
8.1
GV 7000A—Electrical Schematic
1
4
5
7
6
R
5
R
6
7
G
G
2
R
G/Y
G/Y
3
8
9
GV 7000A
Ref.
wc_gr001302
Description
Ref.
Description
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
T
Tan
Gr
Gray
42
Green/Yellow
wc_tx001619gb.fm
GV 7000A / 7003A
8.2
Schematics
GV 7003A—Electrical Schematic
5
1
Br
L
Br
Br
W1V1 U1
V2 U2 W2
B
W
Br
W
Br
B
L
W
Br
B
B
W
7
B
ROTOR
R
4
6
3
B W Br L
W
L
Br
G/Y
10
L
Br
GND
GV 5003A
GV 7003A
1~230V/16A
8
3~400V/16A
9
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
wc_tx001619gb.fm
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
T
Tan
Gr
Gray
43
Green/Yellow