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Nov. 2014
5100003951en / 01
Operator’s manual
Portable generator
GV
7000A
7003A
Manufacturer
Wacker Neuson Produktion GmbH & Co. KG
Preussenstrasse 41
80809 Munich
www.wackerneuson.com
Tel.: +49-(0)89-354 02-0
Fax: +49-(0)89-354 02-390
Original operator's manual
Inhalt
1 Preface
....................................................................................................................... 5
2 Introduction
............................................................................................................... 6
3 Safety Regulations
.................................................................................................... 9
4 Safety and information labels
................................................................................ 18
5 Standard package
................................................................................................... 20
6 Lifting and transporting
......................................................................................... 21
7 Operation
................................................................................................................. 22
8 Maintenance
............................................................................................................ 34
5100003951IVZ.fm
3
9 Basic troubleshooting
............................................................................................ 40
10 Disposal
................................................................................................................... 41
11 Technical data
......................................................................................................... 42
12 Glossary
13 Diagram
EC Declaration of Conformity
................................................................................ 51
DIN EN ISO 9001 certificate
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4
5100003951IVZ.fm
1 Preface
1 Preface
This operator's manual contains information and procedures for the safe operation and safe maintenance of your Wacker Neuson machine. For your own safety and to protect against injuries, you must thoroughly read the safety instructions, familiarize yourself with them and observe them at all times.
This operator's manual is not a manual for extensive maintenance or repair work.
Such work must be carried out by the Wacker Neuson service department or by certified technically trained personnel.
When building this machine, great value was placed on the safety of its operator.
However, an improper operation or improper maintenance can pose dangers.
Please operate and maintain your Wacker Neuson machine in accordance with the information in this operator's manual. It will reward your attention by providing you with a trouble-free service and high level of availability.
Defective machine parts must be exchanged immediately!
Please contact your Wacker Neuson contact partner for questions regarding the operation or maintenance.
All rights are reserved, in particular the right of duplication and distribution.
Copyright 2014 Wacker Neuson Produktion GmbH & Co. KG
This operator's manual - even in part - may only be reproduced, used, copied or distributed with the expressed, prior written consent from Wacker Neuson.
Any type of reproduction, distribution or storage on data carriers in any form or type that is not approved by Wacker Neuson represents a violation of the valid copyright and will be prosecuted.
We reserve the express right to technical modifications that are used to improve our machines or raise the safety standard, even without special notice.
100_0000_0002.fm
5
2 Introduction
2 Introduction
2.1
Means of representation of this operator's manual
Warning symbols
This operator's manual contains safety instructions in the categories:
DANGER, WARNING, CAUTION, ATTENTION.
These are to be followed in order to eliminate the danger of death or injury to the operator, material damage or unprofessional service.
DANGER
This warning notice indicates immediate threatening dangers that can result in death or serious injuries.
You can avoid the danger by following the named measures.
WARNING
This warning notice indicates possible dangers that can result in death or serious injuries.
You can avoid the danger by following the named measures.
CAUTION
This warning notice indicates possible dangers that can result in minor injuries.
You can avoid the danger by following the named measures.
ATTENTION
This warning notice indicates possible dangers that can result in property damage.
You can avoid the danger by following the named measures.
Note
Notice:
You can get additional information here.
Instructions for action
This symbol will prompt you to do something.
1. Numbered instructions for action prompt you to do something in the specified chronological order.
This symbol is used for the listing.
6
100_0000_0003.fm
2 Introduction
2.2
Wacker Neuson Contact partner
Depending on your country, your Wacker Neuson contact partner is your
Wacker Neuson service department, your Wacker Neuson affiliate or your
Wacker Neuson dealer.
You can find the addresses on the Internet at www.wackerneuson.com
.
The manufacturer's address can be found at the beginning of this operator's manual.
2.3
Described equipment types
This operator's manual applies to various versions from one product series. For this reason, some figures may vary slightly in appearance from your equipment.
In addition, components may be described that are not a component of your equipment.
You can find details about the described versions in the chapter
Technical Data
.
100_0000_0003.fm
7
2 Introduction
2.4
Product identification of the equipment
Data of the nameplate
The nameplate contains information that uniquely identifies your equipment. This information is required for ordering spare parts and when inquiring about technical issues.
Write down your equipment's information in the following table:
Item Designation
1 Group and model
2 Year of manufacture
3 Serial number
4 Version no.
5 Item number
Your information
8
100_0000_0003.fm
3 Safety Regulations
3 Safety Regulations
3.1
Safety information in this operator's manual
This operator's manual contains safety regulations in the categories:
DANGER, WARNING, CAUTION,
NOTE
and COMMENT. These are to be followed in order to reduce the danger of injury, damage to equipment or improper service.
This is a safety warning symbol that warns against possible danger of injury.
Comply with all safety regulations that follow this warning symbol.
DANGER
DANGER indicates a hazardous situation that leads to serious injury or death if this warning is not observed.
In order to avoid fatal accidents and serious injuries, observe all safety instructions precisely that follow this signal word.
WARNING
WARNING indicates a hazardous situation that can lead to serious injury or death if this warning is not observed.
In order to avoid possible fatal accidents and serious injuries, observe all safety instructions precisely that follow this signal word.
CAUTION
CAUTION indicates a hazardous situation that can lead to minor to moderate injury if this warning is not observed.
In order to avoid possible minor or moderate injuries, observe all safety instructions precisely that follow
this signal word.
NOTE: When this word appears without a safety warning symbol, NOTE indicates a hazardous situation that can lead to damage if not observed.
Comment: A comment contains additional important information about a work process.
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9
3 Safety Regulations
3.2
Description and purpose of the machine
This machine is a portable power source. The portable generator from
Wacker Neuson consists of a steel pipe frame, which includes a fuel tank, a gasoline engine, a control panel and an electrical alternator. The control panel contains controls and bushings. When the engine is running, the generator converts the mechanical energy into electrical energy. The operator connects electronic loads to the mains sockets.
This machine is used for the electric power supply of connected electronic loads.
See the product specifications for output voltage and frequency of the generator as well as the maximum power limitation of this generator.
This machine was designed and built exclusively for the aforementioned purpose. Use of the machine for any other purpose could permanently damage the machine or cause serious injury to the operator or other persons in the vicinity.
Machine damage due to misuse is not covered by the warranty.
The following practices are considered misuse:
Connection to an electronic load whose voltage and frequency are not compatible with the generator output
Overloading the generator with a load that takes too much power during continuous operation or when starting
Operating the generator in a manner that is inconsistent with the national, statewide and local standards and regulations
Use of the machine as a ladder, support or working surface
Operation of the machine to carry or transport people or equipment
Operation of the machine outside of the plant specifications
Operation of the machine contrary to warning notices attached to the machine and contained in the operator's manual.
This machine was designed and built according to the latest global safety standards. In order to eliminate dangers as much as possible, it was technically designed with great care and contains protective side plates and warning labels for an increased safety of the operator. Additional risks may exist despite these protective measures. These are designated as residual risks. Possible residual risks with this machine:
Heat, noise, exhaust and carbon monoxide from the engine
Risk of fire due to incorrect refueling procedure
Gasoline or gasoline vapors
Electric shock and arc discharge
Injury due to incorrect hoisting technology
For your own protection and the protection of other people, make sure that the safety instructions in this manual have been closely read and understood before starting the machine.
10
100_0402_si_0003.fm
3 Safety Regulations
3.3
Operational safety
DANGER
Carbon monoxide.
The application of a generator in buildings can
LEAD TO DEATH WITHIN MINUTES. The exhaust fumes from the generator contain carbon monoxide (CO). This is an invisible odorless poison. If the exhaust fumes of the generator can be smelled, CO is being inhaled. Even if no exhaust fumes can be smelled, CO could still be being inhaled.
NEVER use the generator in buildings, garages, crawl spaces or other partially enclosed areas. Carbon monoxide can build up to deadly levels in these areas. A fan or open window does NOT provide sufficient fresh air.
ONLY use generators outdoors and far away from windows, doors and aeration. These openings can draw in generator exhaust fumes.
CO can penetrate into a home, even if a generator is used properly. AL-
WAYS use a battery-powered or battery-backup CO alarm in the home.
IMMEDIATELY get to fresh air if you feel unwell, dizzy or weak after using the generator. Consult a physician. It could be carbon monoxide poisoning.
WARNING
Electric shock or risk of fire or explosion. Incorrect connection of the generator to a building's mains supply can lead to current being lead from the generator back into the power supply system. This can cause electric shock, serious injury or death of the worker in the public utility company!
The following connection prerequisites are to be met.
100_0402_si_0003.fm
11
3 Safety Regulations
Connection prerequisites
The following prerequisites are to be met to connect the generator to the building's mains supply.
The generator must meet the prerequisites with regard to performance, voltage and frequency of the equipment.
The generator must be disconnected from the electric power supply.
Connections from the generator to the power supply system of a building must be established by a licensed electrician.
The electrical connections must meet all laws and electrical regulations.
WARNING
Prerequisites for safe operation are familiarity with the machine and proper training.
Machines that are incorrectly operated or that are operated by untrained personnel may pose a danger. Read through the operating instructions in this manual and in the engine manual to make yourself familiar with the job and the proper use of the operator's controls. Inexperienced operators must be instructed by personnel who are familiar with the machine before they are allowed to operate the machine.
3.4
Operator qualifications
Only trained personnel may start, operate and switch off the machine.
The personnel must also have the following qualifications: be trained in the correct operation of the machine be familiar with the necessary safety devices
Access to the machine and operation of the machine is not permitted for:
Children
People under the influence of alcohol, drugs or medication
Personal Protective Equipment (PPE)
The following personal protective clothing (PPE) is to be worn when operating this machine:
Close-fitting work clothes that do not impede movement
Safety glasses with protective sides
Ear protection
Work shoes or boots with toe protection
12
100_0402_si_0003.fm
3 Safety Regulations
NEVER use generator near open containers of fuel, paint or other flammable liquids.
NEVER touch the generator or tools connected to it if you have wet hands.
NEVER use damaged power cables. Electric shock and major machine damage could occur.
NEVER place power cable below the generator or on vibrating or hot parts.
NEVER cover hot or running generator.
NEVER overload generator. The total amperage of the parts connected to the generator may not exceed the output limit.
NEVER operate the machine in snow, rain or standing water.
NEVER allow untrained personnel to operate or maintain the generator.
Familiarize yourself with the operation and shutdown before starting the generator.
ALWAYS store the machine properly when not in use. Store the machine in a clean dry place and keep it out of reach of children.
ALWAYS make sure that the machine is stable and cannot tip, roll, slide or fall during operation.
ALWAYS transport the generator in an upright position.
ALWAYS keep at least one meter distance from facilities, buildings or other machines while operating the machine.
ALWAYS keep the area immediately around and under the machine clean, tidy and free of grime and flammable materials. Check that there is also no grime above the machine that could fall onto or into the machine or the exhaust area.
ALWAYS keep all tools, power cables and other loose objects away from the generator before starting.
Do NOT ground this generator.
If more than one electronic device is connected to the generator, the additional connected electronic equipment must be connected to the generator via an isolating transformer or a suitable FI switch (PRCD), whereby each additional electronic device must be operated via a separate isolating transformer or PRCD.
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13
3 Safety Regulations
Generator vibration
Generators vibrate during normal operation. Check during and after use of the generator whether the generator or the extension cord and power cable show damage due to vibration.
Repair any damage as needed or replace the parts affected.
Do not use any plugs or cables that show signs of damage, such as damaged or cracked insulation or blades.
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100_0402_si_0003.fm
3 Safety Regulations
3.5
Safety when using combustion engines
WARNING
Combustion engines pose a particular danger during operation and when refueling. Failure to follow the warning notices and safety standards can lead to serious injury or death.
Read and always observe the warning notices in the operator's manual of the engine and the safety instructions below.
DANGER
Carbon monoxide.
Use of the generator in buildings can LEAD TO DEATH
WITHIN MINUTES. The exhaust fumes from the generator contain carbon monoxide (CO). This is an invisible odorless poison. If the exhaust fumes of the generator can be smelled, CO is being inhaled. Even if no exhaust fumes can be smelled, CO could still be being inhaled.
Operational safety
When running the engine:
Keep the area around the exhaust pipe free of flammable materials.
Inspect the fuel lines and fuel tank for leaks and cracks before starting the engine. Do not operate the machine if there are leaks or if the fuel lines are loose.
When running the engine:
Do not smoke while operating the machine.
Do not operate the engine near sparks or open flames.
Do not touch the engine or the muffler while the engine is running or shortly after switching the engine off.
Do not operate the machine with a loose or missing fuel cap.
Do not start the engine if fuel has been spilled or there is an odor of gas. Move the machine away from the spilled fuel and wipe away the spilled fuel before starting.
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15
3 Safety Regulations
Safety when refueling
When refueling the machine:
Immediately wipe away any spilled fuel.
Fill the fuel tank in a well-ventilated area.
Reattach the fuel tank cap after refueling.
Do not smoke.
Do not refuel hot or running engines.
Do not refuel the engine near sparks or open flames.
Do not refuel the machine while it is on plastic-coated surfaces of pick-ups.
Static electricity can ignite the fuel or fuel vapors.
3.6
Service safety
WARNING
Carelessly maintained machines can pose dangers!
Regular maintenance and occasional repairs are necessary to ensure the safe and correct functioning over longer time periods. If problems should occur with the generator or while the machine is being maintained, always attach a "DO
NOT START" sign to the control panel in order to alert others of this.
Personal Protective Equipment (PPE)
Wear the following personal protective equipment during maintenance or repair work:
Close-fitting work clothes that do not impede movement
Safety glasses with protective sides
Ear protection
Work shoes or boots with toe protection
Additional notes before operating the machine:
Tie up long hair.
Take off all jewelry (including rings)
16
100_0402_si_0003.fm
3 Safety Regulations
Do NOT use any gasoline or other types of fuel or flammable solvents to clean the machine parts, especially not in closed areas. The vapors from fuels and solvents may explode.
NEVER operate equipment without protective devices or with damaged protective devices.
NEVER modify the machine without written approval from the manufacturer.
NEVER allow water to collect at the bottom of the generator. If water should collect, remove the generator and allow it to dry thoroughly before maintaining.
NEVER maintain the machine with wet clothing or wet skin.
NEVER have the machine serviced by untrained personnel. Electronic elements of this machine should only be maintained by qualified electricians.
ALWAYS keep the machine clean and ensure that the labels are legible. Replace all missing and hard-to-read labels. The labels contain important operating instructions and warn against dangers.
ALWAYS reattach protective devices and safety equipment to the unit after repair and maintenance.
ALWAYS allow the engine to cool completely before transport.
ALWAYS watch out for the rotating parts of the generator and engine and keep hands, feet and loose clothing parts away from these rotating parts.
ALWAYS switch the engine off before maintenance. Disconnect the negative connection of the battery on machines with electric starters.
ALWAYS keep fuel lines in a good condition and connected correctly. Leaking fuel and gases are highly explosive.
If spare parts are required for this machine, only use parts from
Wacker Neuson or parts that match the original exactly in terms of dimensions, model, intensity and material.
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17
4 Safety and information labels
4 Safety and information labels
There are labels on your equipment that contain important information and safety instructions.
Keep all labels legible.
Replace missing or illegible labels.
The item numbers on the labels can be found in the parts book.
Item Label
1
Description
Guaranteed sound power level.
2
3
DANGER!
Danger of suffocation.
Engines give off carbon monoxide.
Do not run the machine indoors or in
enclosed areas.
NEVER operate in houses or garages,
EVEN IF doors and windows are open.
Only use OUTDOORS and away from
windows, doors and aeration.
Read through the operator's manual.
No sparks, flames or burning objects are permitted near the machine.
Stop the engine before refueling.
Warning against hot surface.
4 Warning against hot surface.
PE = Potential grounding - Connect cable from grounding rod here.
WARNING!
Electric shock will cause serious injury or death.
18
100_0402_ls_0004.fm
Item Label
5
4 Safety and information labels
Description
When connecting more than one piece of electronic equipment,
special precautions must be taken.
Read through the operator's manual.
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5 Standard package
5 Standard package
The standard package includes:
Equipment.
Operator's manual.
Parts book.
General safety instructions.
20
100_0402_sd_0001.fm
6 Lifting and transporting
6 Lifting and transporting
Lifting the machine
This compact generator is heavy enough to cause injury in the event of incorrect hoisting technology. Observe the following instructions to lift the generator:
Do not try to lift the generator without help. Use suitable lifting bars e. g. loops, chains, twisting hooks, ramps or car jacks.
Make sure that the lifting bars are firmly attached and have sufficient carrying capacity to safely lift or hold the generator.
Pay attention to surrounding persons when lifting the generator.
Transporting the machine
Observe the following instructions when the generator is transported from and to the construction site.
Allow the engine to cool off before refueling the generator.
Empty the fuel tank.
Close the fuel cock.
Firmly fasten the generator to the transport vehicle so that it does not slide or tip over.
Do not refuel the generator in or on the transport vehicle. Transport the generator to the work location first and refuel the fuel tank there.
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7 Operation
7 Operation
7.1
Prepare the machine for first-time application
Prepare the machine for first-time application:
1. Ensure that all loose packaging material has been removed from the machine.
2. Check the machine and its components for damage. Do not operate the machine if you find visible damage! Ask the Wacker Neuson dealer for advice at once.
3. Check whether all of the parts belonging to the machine have been delivered and whether all loose parts and fasteners are present.
4. Now attach components that are not yet fastened.
5. Fill fluids as needed, including fuel, engine oil and battery acid.
6. Bring the machine to its site of operation.
DANGER
Carbon monoxide.
The application of a generator in buildings can
LEAD TO DEATH WITHIN MINUTES. The exhaust fumes from the generator contain carbon monoxide (CO). This is an invisible odorless poison. If the exhaust fumes of the generator can be smelled, CO is being inhaled. Even if no exhaust fumes can be smelled, CO could still be being inhaled.
NEVER use the generator in buildings, garages, crawl spaces or other partially enclosed areas. Carbon monoxide can build up to deadly levels in these areas. A fan or open window does NOT provide sufficient fresh air.
ONLY use generators outdoors and far away from windows, doors and aeration. These openings can draw in generator exhaust fumes.
CO can penetrate into a home, even if a generator is used properly. AL-
WAYS use a battery-powered or battery-backup CO alarm in the home.
IMMEDIATELY get to fresh air if you feel unwell, dizzy or weak after using the generator. Consult a physician. It could be carbon monoxide poisoning.
Use of gasoline / ethanol mixtures
This portable generator may not be used with gasoline / ethanol mixtures with more than 15 % ethanol content.
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7 Operation
7.2
Power requirements
The Wacker Neuson generator GV 7000A is designed for the operation of singlephase 50 Hz electronic devices for 230 VAC. Generator
GV 7003A
is designed for the operation of single-phase 50 Hz electronic devices for 230 VAC and/or triple-phase 50 Hz electronic devices for 400 VAC. The single-phase or triplephase sides can be used at the same time.
NOTE
:
Do not exceed the performance limit of the generator, as this may lead to damage of the generator or the tools. See Technical Data.
Check the nameplates or labels of the tools and electronic equipment to be connected to ensure that the current values conform with those of the generator.
Always inquire with the manufacturer if equipment is lacking the wattage.
Some electrical equipment requires a great amount of power to start than to operate. The generator must be able to convey this power. Different equipment designs actually require more current than specified on the nameplate.
The "general power requirements when starting" information only applies as a general guideline to assist you in determining the power requirements. The nearest Wacker Neuson dealer, tool manufacturer or dealer can help you if you have questions.
NOTE
:
Do not exceed the specified current intensity limit at any plug receptacle.
NOTE
:
If a tool or electrical equipment should not reach the full RPM a few seconds after starting, switch it off immediately in order to prevent damage.
General power requirements for starting
White light bulbs and electronic goods, such as irons and hot plates, use a resistor heating element and require the same amount of power during startup that is listed on the nameplate.
When starting, neon and mercury lamps require 1.2-2 times the specified wattage.
Many electric motors and power tools use a large amount of power when starting. The electrical supply required during start-up depends on the type of motor and the intended application.
When starting, most power tools require 1.2-3 times the specified wattage.
Connection units, such as submersible pumps and air compressors, require a large amount of power when starting, even up to 3-5 times the specified wattage.
If the wattage of a tool or electrical equipment is not specified, this can be calculated by multiplying the voltage requirements with the amperage requirements.
Single-phase: VOLTS x AMPS = WATTS
Three-phase: VOLTS x AMPS x 1.732 x 0.8 = WATTS
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7 Operation
7.3
Installation
Set up the generator so it is protected from rain, snow or other forms of moisture.
The ground must be solid and level in order to prevent slipping or displacement.
Do not direct the engine exhaust to an area with people.
Both the work area as well as the components must be protected from all forms of moisture.
7.4
Current depreciation
Generators run differently due to altitude and temperature differences.
Unmodified internal combustion engines have reduced performance at high altitudes due to the lower air pressure. This means less performance and therefore a reduced power exploitation. As soon as temperatures increase, an engine runs less economically and electrical components have more resistance.
For every 500 meters above high altitudes of 1000 meters above sea level, the performance of the generator is reduced by 3%. For outside temperatures above
40 degrees Celsius, the generator performance is reduced by 3% for every additional 5 degrees. The tables shown help with the high altitude and outside temperature performance devaluation. In order to determine the true generator performance, it may be necessary to consider both the high altitude and temperature devaluation factors.
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100_0402_op_0003.fm
7 Operation
Outside temperature
°C
45
50
55
60
High altitude m
1500
2000
2500
3000
3500
4000
Devaluation
3 %
6 %
9 %
12 %
Devaluation
3 %
6 %
9 %
12 %
15 %
18 %
Factor
0.97
0.94
0.91
0.88
Factor
0.97
0.94
0.91
0.88
0.85
0.82
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25
7 Operation
7.5
Ground
CAUTION
The mid-point (neutral) conductor of this equipment is not grounded.
Do not drive the PE rod into the ground under normal operating conditions.
Refer to the local regulations if the equipment is intended to power a building or similar system.
wc_gr001286
For generator sets that are to supply a facility in a TT network, or if residual current protection is required in the TT network, or if this equipment must be used for additional protection due to conditions or regulations, only 30 mA residual current protective switches may be used as protective devices. The 30 mA residual current protective switch must be installed ON the generator set itself, but at least on the nearest possible position in relation to the generator set. Only with this type of installation is it allowed and necessary to establish the ground connection of the generator framework via the point provided on the frame (see ground symbol 5019).
7.6
Heavy duty operation
Do not operate this generator for longer than 20-30 minutes under maximum electrical load rating. For continuous operation, do not exceed the continuous
(prime) power output of the generator. See technical data of the generator in this operator's manual.
26
100_0402_op_0003.fm
7 Operation
7.7
Use of extension cables
A loss of power takes place when connecting electrical equipment or a tool to the generator with an extension cable — the longer the cable, the greater the loss of power. This means that less voltage is conveyed to the electrical equipment and the power consumption is increased or the performance is reduced. A larger extension cable diameter reduces the loss of voltage.
NOTE
:
Operation of electrical equipment under low voltage may lead to overheating.
The table serves as a guideline for selecting the correct cable size.
Only strong, rubber-covered cables can be used that correspond to regulation
IEC 245-4.
WARNING
Damaged cables may cause electric shock, which can lead to serious injury or death.
NEVER use worn, bare or frayed cables. Replace damaged cables immediately.
Never exceed the cable's rated power.
Contact the cable manufacturer if you have questions about using the cable.
Select the cable size from the table
Minimum cross-section of extension cables
or calculate the minimum cross-section using the graph
Minimum cross-section of extension cables.
The X-axis of the graph stands for the values A x m (ampere x meter). The Y-axis stands for the cross-section in mm². Multiply the steady state (operating) current for the load in ampere (A) with the desired length of the extension cable in meters (m). Now look for your result on the X-axis. Go along the graph until you have found the point for your field of application. Now read the recommended minimum cable length on the Y-axis.
Example
For example, if there is a triple-phase application with 400 V of steady state
(operating) current available for the load at 15 A and the desired extension cable length is 100 m, then:
15 A x 100 m = 1500 A x m.
1500 A x m = 2.5 mm².
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27
7 Operation
Table for extension cable minimum size
10
15
20
30
40
6
8
2
4
Ampere- performanc e variable
25
1.5
1.5
1.5
2.5
4
1.5
1.5
1.5
1.5
Extension cable minimum size
230V/1~/50Hz 400V/3~/50Hz
Length in m Length in m
50
1.5
1.5
1.5
1.5
1.5
2.5
4
4
6
100 200 25
Diagram for extension cable minimum size
50
Cross-section surface in mm
2
6
10
4
4
16
1.5
1.5
1.5
2.5
1.5
2.5
4
6
6
10
16
25
---
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
2.5
4
1.5
1.5
1.5
1.5
100
1.5
2.5
4
6
6
1.5
1.5
1.5
1.5
200
6
10
4
6
---
1.5
1.5
2.5
2.5
25
16
mm
2
10
6
4
2.5
1.5
0 1000
2000
3000
A x m
1~ 23
3~ 40
0V 50
0V 50
4000
Hz
Hz
5000
6000
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100_0402_op_0003.fm
7 Operation
7.8
Control Panel
See blueprints: wc_gr001275 and wc_gr001369
The fuse protects the generator from significant overloads or short circuits. If the fuse opens, shut down the engine immediately and determine the cause by starting the engine again. Check the electrical equipment and tools connected to the generator and make sure that their power requirements do not exceed the performance limit of the generator or the power limitations of the plug receptacle.
Comment:
The protective covers are only missing in the enlarged plug receptacles for reasons of identification. Never remove the protective cover.
d1 d2 c b a d3 d4
GV 7000A
No.
a
Description
Main safety cutout - 22A c Plug receptacle, CEE, IP44
230V, 32A d1 Plug receptacle, Schuko IP44 (CEE 7)
230 V, 16 A d3 Plug receptacle (Switzerland)
230 V, 16 A wc_gr001275
No.
b
Description
Main safety cutout - 12A d2 d4
Plug receptacle, CEE, IP44 2P+E
230 V, 16 A
Plug receptacle (French)
230 V, 16 A
100_0402_op_0003.fm
29
7 Operation d1 d2 c d3 d4
No.
c
Description
Main circuit breaker -10 A,12 A,10 A 3pin d1 Schuko IP54 (CEE 7) plug receptacle
230 V, 16 A d3 Swiss plug receptacle
230 V, 16 A e1 CEE plug receptacle IP44 3P+N+E
400 V, 3 Ø, 16 A
No.
Description
d2 d4 e2
CEE plug receptacle IP44 2P+E
230 V, 16 A
French plug receptacle
230 V, 16 A
Swiss plug receptacle
400 V, 3 Ø, 16 A
30
100_0402_op_0003.fm
7 Operation
7.9
Before starting
DANGER
Carbon monoxide.
The application of a generator in buildings can
LEAD TO DEATH WITHIN MINUTES. The exhaust fumes from the generator contain carbon monoxide (CO). This is an invisible odorless poison. If the exhaust fumes of the generator can be smelled, CO is being inhaled. Even if no exhaust fumes can be smelled, CO could still be being inhaled.
1. Read and understand the safety and operator's manual at the start of these operating instructions.
2. Read and understand all statements of the safety and warning signs.
3. Check:
Engine oil level.
Fuel level.
State of the air cleaner.
Tight fit of the outer bracket.
State of the fuel lines.
100_0402_op_0003.fm
31
7 Operation
7.10
Starting
See blueprints: wc_gr001299
1. Disconnect all connections from the generator and put the main circuit breaker in an open position
(e2)
.
2. Open fuel shut-off valve
(a)
.
Comment:
Close the choke
(b)
if the engine is cold (pull out). Open the choke if the engine is warm (push
).
3. Put engine switch to “ON”
(c1)
and pull starter rope
(d)
.
Comment:
Do not start the engine if the oil level is low. In this case, check the engine oil level and top off if necessary
.
4. Open the choke while the engine is warming up
(b)
.
5. Put main circuit breaker in the closed position
(e1)
. Allow the engine to warm up for a few minutes before connecting electrical equipment.
e2 b e1 c2 c1 d a
wc_gr0012 99
7.11
Stopping
See blueprints: wc_gr001299
1. Switch off all electrical equipment and tools and disconnect from the generator.
2. Put the engine switch in the "OFF" position
(c2)
.
3. Close the fuel shut-off valve.
Comment:
To turn off quickly in cases of emergency, put the engine switch in the "OFF" position
(c2)
.
32
100_0402_op_0003.fm
7 Operation
7.12
Emergency stop procedure
Procedure
In the case of an accident of a failure of the machine during operation, the following procedure is to be applied:
1. Stop the engine.
2. Shut off the fuel supply.
3. Disconnect the tools from the machine.
4. Let the machine cool.
5. Please contact the machine rental or machine owner for additional manuals.
100_0402_op_0003.fm
33
8 Maintenance
8 Maintenance
8.1
Period maintenance schedule
The following table contains the basic maintenance jobs for the machine. Jobs selected with a check mark can be performed by the operator. The jobs marked with a small box require special training and special equipment.
Check the fuel level.
Check the engine oil level.
Check the air cleaner. Replace when necessary.*
Check external fastening parts.
Clean air cleaner elements.*
Check shockmount for damage.
Change the engine oil.*
Check and clean spark plug.
Check and adjust the valve interval.
Clean fuel tank.*
Check the fuel line.
Replace when necessary.
* Clean more often in dusty areas.
Daily before
Operation
After the first
20 hours
Every
50 hours
Every
100 hours
Every
300 hours
34
100_0402_mt_0001.fm
8 Maintenance
8.2
Engine oil
See blueprint: wc_gr000022
1. Drain the engine oil when the engine is warm.
2. Remove the sealing plug
(a)
and the drain plug
(b)
to drain the oil.
Comment:
For environmental reasons, a bin should be placed under machine to catch the fluid and a waterproof sheet should also be placed under the machine to protect the ground. The fluid must be dispose of according to the relevant regulations.
3. Reinsert the drain plug.
4. Fill the engine crankcase with the recommended engine oil up to the oil level marking
(c)
. For the oil quantity and type, see
Technical Data
.
5. Screw the sealing plug back in.
wc_gr000022
100_0402_mt_0001.fm
35
8 Maintenance
8.3
Air cleaner maintenance
See blueprint: wc_gr0001287
This engine is outfitted with a single-element air cleaner.
Frequent cleaning of the air cleaner prevents carburetor malfunctions.
WARNING
NOTE
: NEVER
run the engine without an air cleaner, as this can result in major engine damage.
NEVER
clean air cleaner with gasoline or other solvents with a low combustion point, as this can result in fire or explosions.
Maintenance:
1. Loosen the locks
(a)
on the upper and lower sides of the air cleaner (filter) cover
(b)
.
2. Check the filter element
(c)
. Replace if damaged.
3. Clean filter element in warm water and mild laundry soap. Wash out with clean water thoroughly. Allow element to dry thoroughly. Impregnate the element in clean engine oil and press out the excessive oil.
4. Reattach the element and air cleaner (filter) cover.
a c b
wc_gr001287
36
100_0402_mt_0001.fm
8 Maintenance
8.4
Spark plug
See blueprint: wc_gr000028
Clean or replace the spark plug as needed. See engine manual.
The exhaust will become very hot during operation and also remains hot for a while after the engine is switched off. Never touch a hot exhaust.
WARNING
Comment:
See the technical data for the recommended spark plug and spark plug air gap.
1. Remove and check the spark plug.
2. Replace the spark plug if the isolator is cracked or split.
3. Clean spark plug electrodes with a wire brush.
4. Adjust the spark plug air gap
(a)
.
5. Screw in and tighten the spark plug.
NOTE
:
A loose spark plug can become very hot and lead to engine damage.
100_0402_mt_0001.fm
37
8 Maintenance
8.5
Engine speed
See blueprints: wc_gr001300
Generators require a non-adjustable engine speed in order to maintain the correct voltage. The engine speed is controlled by a governor that automatically adjusts to the changing loads of the engine in order to maintain a constant RPM.
There is no gas regulator.
To set the correct engine speed:
Unscrew the RPM adjusting screw
(a)
in and out until a zero load RPM of 3100
RPM is reached.
NOTE
:
Tools and other electrical equipment can be damaged if the engine speed is set too high or too low.
Use the technical data to set engine speed without load or idle.
1. Start the engine and allow it to warm up to the normal operating temperature.
2. Screw in the choke coil stop screw
(a)
to increase the speed. Unscrew the choke coil stop screw to reduce the speed. Ensure that the throttle lever is touching the choke coil stop screw before measuring the RPM.
a
wc_gr001300
38
100_0402_mt_0001.fm
8 Maintenance
8.6
Long-term storage
Before long-term storage:
1. Put engine fuel shut-off valve in the closed position.
2. Disconnect fuel line from the carburetor. Place the open end of the line in an appropriate bin and open the fuel shut-off valve to empty the tank.
Gasoline is highly flammable. Drain the fuel tank in a well-vented area and away from flames or sparks.
WARNING
3. Open the drain plug on the carburetor and drain any remaining fuel from the carburetor.
4. Change the engine oil.
5. Remove the spark plug and pour about 30 ml of clean engine oil in the cylinder. Turn the engine over a few times to spread the oil on the inner walls of the cylinder.
6. Pull the starter rope slowly until you notice resistance and put the handle in this position. This ensures that the intake and exhaust vales are closed.
7. Store the generator in a dry and clean place.
100_0402_mt_0001.fm
39
9 Basic troubleshooting
9 Basic troubleshooting
Problem / symptom
Check the following if the engine does not start:
Cause / remedy
Engine switch is in the "Start" position.
Fuel cock is open.
Fuel is replenished.
Choke lever is in the correct position. The choke should be closed when starting a cold engine.
No electronic equipment is connected to the generator.
Spark plug is in good condition.
Spark plug cap is firmly seated.
Engine oil level is sufficient.
Fuse switch is closed.
Wiring from the generator to the plug receptacles is secured.
Check the following if the engine starts, but the generator does not deliver any power to plug receptacles:
Check the following if the engine starts, but runs irregularly:
Air cleaner condition.
Condition of the spark plug and spark plug cap.
How new the fuel is.
40
100_0402_ts_0001.fm
10 Disposal
10 Disposal
10.1
Disposal of old electrical and electronic equipment
For customers in EU countries
This equipment is subject to the European directive for old electrical and electronic equipment (Waste Electrical and Electronic Equipment - WEEE) as well as the corresponding national laws. The WEEE directive provides the framework for an EU-wide treatment of old electrical equipment.
The equipment is marked with the adjacent symbol of a crossed-out garbage can. This means that you may not dispose of the equipment via the normal house waste, but rather it must be disposed of in a separate collection in an environmentally friendly manner.
This equipment is provided as a professional electrical tool exclusively for commercial use (so-called B2B device according to WEEE directive).
Unlike equipment mostly used in private households (so-called B2C devices), this equipment may therefore not be disposed of in some EU countries, such as in Germany, at the collection points of public waste management organizations
(e.g. municipal collection stations). If you are in doubt about where to dispose of your equipment, please ask your sales outlet about the proper disposal procedure for B2B electrical equipment in your country and ensure the disposal takes place according to the valid statutory provisions. Please also observe any information regarding disposal in the purchase contract or in the general terms and conditions of your sales outlet.
A professional disposal of this equipment avoids negative effects on human health and the environment, helps with the targeted treatment of pollutants and makes it possible to recycle valuable raw materials.
For customers in other countries
A professional disposal of this equipment avoids negative effects on human health and the environment, helps with the targeted treatment of pollutants and makes it possible to recycle valuable raw materials. We therefore recommend not disposing of this equipment via the normal household waste, but rather in a separate collection in an environmentally friendly manner. National laws also may under certain circumstances prescribe the separate disposal of electrical and electronic products. Please ensure the disposal of this equipment according to the provisions applicable in your country.
100_0000_0004.fm
41
11 Technical data
11 Technical data
11.1
GV 7000
Designation
Item number
Unit
Peak performance (LTP) kW
Continuous (prime) power output (COP) kW
Net installed power (PRP) kW
Length mm
Width
Height mm mm
Weight
Operating weight
Generator model
Insulation class kg kg
Output current 1~
Output frequency
Power factor
Nominal speed
Phases
Type of mains
Total harmonic distortion
(THD)
A
Hz cos rpm
~
%
Start-up behavior (ICC)
Tank capacity
Main fuse
Available voltages 1~
Plug receptacles
A
V l
In
GV 7000A
0009348
5.4
5.0
GV 7000A
0009353
5.4
5.0
GV 7000A
5100006205
5.4
5.0
5.2
729
500
536
73
79
NSM K100G
H
5.2
729
500
536
73
79
NSM K100G
H
5.2
729
500
536
73
79
NSM K100G
H
25.1
50
0.9
3,000
25.1
50
0.9
3,000
25.1
50
0.9
3,000
1 1 1
Protective breaker Protective breaker Protective breaker
6 6 6
3-4
11.0
25
230
Model F: 230V
16A 1~ CEE7/4,
CEE 3P 32A 6h
230V 50Hz
3-4
11.0
25
230
Model E: 230V
16A 1~ CEE7/5,
CEE 3P 32A 6h
230V 50Hz
3-4
11.0
25
230
Model F: 230V
16A 1~ CEE7/4,
CEE 3P 32A 6h
230V 50Hz
42
100_0402_td_0004.fm
11 Technical data
Designation
Plug receptacles
Design class
Unit
Quantity
Protection rating
Operating temperature range
Max. operating height
°C
Measured sound power level L wa
Guaranteed m NN
Sound pressure level L pA
* dB(A)
Standards dB(A) dB(A)
Standards
* Measured at 7meter's distance.
GV 7000A
2
G1
IP23
-15 – +40
1,500
69.0
97
97
GV 7000A
2
G1
IP23
-15 – +40
1,500
69.0
DIN EN ISO 11201
97
97
2000/14/EC
GV 7000A
2
G1
IP23
-15 – +40
1,500
69.0
97
97
100_0402_td_0004.fm
43
11 Technical data
11.2
GV 7003
Designation
Item number
Peak performance 1~
(LTP)
Peak performance
3~(LTP)
Unit
kW kW
Continuous (prime) power output 1~(COP) kW
Continuous (prime) power output 3~(COP) kW
Net installed power (PRP) kW
Length mm
Width
Height mm mm
Weight
Operating weight
Generator model
Insulation class kg kg
Output current 1~
Output frequency
Power factor
Nominal speed
Power factor 3~
Phases
Type of mains
Total harmonic distortion
(THD)
Start-up behavior (ICC)
Voltage accuracy
Output current 3~
A
Hz cos rpm cos
~
%
In
%
A
44
GV 7003A
5100002155
3.4
6.0
3.2
5.7
5.6
729
500
536
81
86
NSM T100SC
H
14.1
50
0.9
3,000
0.8
3
Protective breaker
6
3-4
6
10.8
100_0402_td_0004.fm
11 Technical data
Designation
Tank capacity
Main fuse
Available voltages 3~
Available voltages 1~
Plug receptacles l
Unit
A
V
V
Plug receptacles
Design class
Quantity
Protection rating
Operating temperature range
Max. operating height
°C m NN
Sound pressure level L pA
* dB(A)
Standards
Measured sound power level L wa
Guaranteed dB(A) dB(A)
Standards
* Measured at 7meter's distance.
GV 7003A
11.0
10
400
230
CEE 3P 16A 6h 230V 50Hz, CEE 4P 16A 6h 400V 50Hz,
Model F: 230V 16A 1~ CEE7/4
3
G1
IP23
-15 – +40
1,500
69.0
DIN EN ISO 11201
97
97
2000/14/EC
100_0402_td_0004.fm
45
11 Technical data
11.3
Combustion engine
Designation
Manufacturer
Type of engine
Combustion method
Cooling
Cylinders
Displacement
Max. slanting position cm
3
°
Fuel type
Fuel consumption
Mixture preparation
Tank capacity l/h l
Oil specification
Max. oil filling
Max. performance l kW
RPM rpm
Standards
Rated power
Nominal speed
Standards
Exhaust limit values
Spark plug type
Spark plug air gap
Starter type kW rpm mm
Honda
GX390RT2-VPX9-OH
Four-cycle
Air cooling
1
389
20
Gasoline
2.1
Carburetor
11.0
SAE 10W-40
1.1
7.0
3,600
SAE J1349
6.4
3,000
SAE J1349
CARB, EPA, EU
NGK BPR-6 ES
0.7
Recoil starter
46
100_0402_td_0004.fm
12 Glossary
12 Glossary
Class rating
The class rating according to DIN EN 61140 marks electrical machines in terms of security measures for the prevention of an electric shock. There are four class ratings:
I
Class rating
0
II
III
Significance
No special protection apart from the basic insulation.
No grounded conductor.
Plug connection without a grounded conductor contact.
Connection of all conductive housing components to the grounded conductor.
Plug connection with a grounded conductor contact.
Reinforced or double insulation (protective insulation).
No connection to the grounded conductor.
Plug connection without a grounded conductor contact.
Machines are operated with a protective low voltage
(<50 V).
Connection to the grounded conductor is not necessary.
Plug connection without a grounded conductor contact.
100_0000_0005.fm
47
12 Glossary
Protection rating IP
The protection rating DIN EN 60529 indicates the suitability of electrical machines for certain environmental conditions and also the protection against hazards.
The protection rating is specified with an IP code according to DIN EN 60529.
Code Significance of 1st digit:
Protection against contact with hazardous parts.
Protection against ingress of foreign bodies.
0
1
Not protected against contact.
Not protected against foreign bodies.
Protected against contact with the back of the hand.
Protected against large foreign bodies with a diameter of >50 mm.
2
3
4
5
6
Protected against contact with a finger.
Protected against medium-sized foreign bodies (diameter >12.5 mm).
Protected against contact with a tool (diameter >2.5 mm).
Protected against small foreign bodies (diameter of >2.5 mm).
Protected against contact with a wire (diameter >1 mm).
Protected against particle shape foreign bodies (diameter >1 mm).
Protected against contact.
Protected against dust deposits inside.
Completely protected against contact.
Protected against dust ingress.
4
5
2
3
Code Significance of 2nd digit:
Protection against ingress of water
0
1
Not protected against water penetration.
Protected against vertically falling drip water.
Protected against angled falling drip water (15° inclination).
Protected against spray water (60° inclination).
Protected against splash water from all directions.
Protected against water jets (nozzle) from any angle.
6
7
8
Protected against powerful water jets (flooding).
Protected against temporary submersion in water.
Protected against continuous submersion in water.
48
100_0000_0005.fm
13 Diagram
13.1
GV 7000A - Wiring diagram
13 Diagram
Ref.
1
2
3
4
5
Description
Main stator windings
Auxiliary winding
Capacitor
Rotor windings
Diode
Ref.
R
T
L
P
B Black
G Green
Blue
Pink
Red
Light brown
Color chart
V Purple
W White
Y Yellow
Br Brown
Cl Clear
Gr Gray
8
9
6
7
Description
Surge absorber
Circuit breaker
Plug receptacle 230V, 1Ø, 16 A
Plug receptacle 230V, 1Ø, 32 A
Or
Pr
Sh
LL
G/Y
Orange
Purple
Casing
Light blue
Green/Yellow
100_0402_ew_0004.fm
49
13 Diagram
13.2
GV 7003A - Wiring diagram
1 5
Br
W
B
Br
B
W
4
ROTOR B
R
L
3
W
Br
10
Br
Br
L
6
W1 V1 U1
V2 U2 W2
Br
B
Br
B
W
W
L
GV 5003A
GV 7003A
Ref.
1
2
3
Description
Main stator windings
Auxiliary winding
Voltage regulator (current rectifier)
4 Rotor windings
5 Compound (transformer)
7
B W Br L
3~400V/16A
9
G/Y
L
Br
GND
1~230V/16A
8 wc_gr00124 9
Ref.
Description
6 Terminal board
7 Circuit breaker
8 Plug receptacle
230 V, 1Ø, 16A
9 Plug receptacle
400 V, 3 Ø, 16 A
10 Brushes
L
P
B Black
G Green
Blue
Pink
R Red
T Light brown
Color chart
V Purple
W White
Y Yellow
Br Brown
Cl Clear
Gr Gray
Or
Pr
Sh
LL
G/Y
Orange
Purple
Casing
Light blue
Green/Yellow
50
100_0402_ew_0004.fm
EC Declaration of Conformity
Manufacturer
Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München
Product
Product
Product category
Product function
Item number
Net installed power
Measured sound power level
Guaranteed sound power level
Generator
Electricity generation
0009348 0009353
5.2 kW
97 dB(A)
5.2 kW
97 dB(A)
97 dB(A)
GV 7000A
97 dB(A)
5100006205
5.2 kW
97 dB(A)
97 dB(A)
GV 7003A
5100002155
5.6 kW
97 dB(A)
97 dB(A)
Conformity assessment procedure
According to 2000/14/EC, Appendix VIII.
Notified body
SNCH Société Nationale de Certification et ’Homologation, L-5230 Sandweiler
Directives and standards
We hereby declare that this product meets and complies with the relevant regulations and requirements of the following directives and standards:
2006/42/EC, 2006/95/EC, 2000/14/EC, 2004/108/EC, 2011/65/EU
Authorized person for technical documents
Axel Häret,
Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München
Munich, 29 October 2014
Helmut Bauer
Managing Director
Translation of the original Declaration of Conformity
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