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Wacker Neuson G 7Ai Operator's Manual

Summary of G 7Ai

  • Page 1

    Generator g 7ai operator’s manual 0152817en 003 0309 0 1 5 2 8 1 7 e n.

  • Page 2

    Danger carbon monoxide using a generator indoors can kill you in minutes. Generator exhaust contains carbon monoxide (co). This is a poison you cannot see or smell. If you can smell the generator exhaust, you are breathing co. But even if you cannot smell the exhaust, you could be breathing co. • ne...

  • Page 3: G 7Ai

    G 7ai table of contents wc_bo0152817en_003toc.Fm 1 1. Foreword 3 2. Safety information 4 2.1 operating safety .................................................................................. 5 2.2 operator safety while using internal combustion engines .................. 6 2.3 service safety ........

  • Page 4: Table of Contents

    Table of contents g 7ai wc_bo0152817en_003toc.Fm 2 5. Maintenance 26 5.1 engine maintenance ............................................................................26 5.2 periodic maintenance schedule ..........................................................26 5.3 engine oil ......................

  • Page 5

    Wc_tx000001gb.Fm 3 california proposition 65 warning: engine exhaust, some of its constituents, and certain vehicle components, contain or emit chemicals known to the state of california to cause cancer and birth defects or other reproductive harm. 1. Foreword this manual provides information and pr...

  • Page 6: Safety Information

    Safety information g 7ai wc_si000088gb.Fm 4 2. Safety information this manual contains danger, warning, caution, and note callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol. It is used to alert y...

  • Page 7: G 7Ai

    G 7ai safety information wc_si000088gb.Fm 5 2.1 operating safety backfeed from the generator into the public power distribution system can cause serious injury or death to utility workers! Improper connection of generator to a building's electrical system can allow electrical current from the genera...

  • Page 8: Safety Information

    Safety information g 7ai wc_si000088gb.Fm 6 2.1.10 always store the equipment properly when it is not being used. Equipment should be stored in a clean, dry location out of the reach of children. 2.1.11 always position and operate the generator on a firm, noncombustible, level surface. 2.1.12 always...

  • Page 9: G 7Ai

    G 7ai safety information wc_si000088gb.Fm 7 2.3 service safety poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. If the generator is experiencing pro...

  • Page 10: Safety Information

    Safety information g 7ai wc_si000088gb.Fm 8 2.4 label locations 2 - 15 11 56 danger gefahr danger peligro stop.

  • Page 11: G 7Ai

    G 7ai safety information wc_si000088gb.Fm 9 2.5 safety and operating labels wacker machines use international pictorial labels where needed. These labels are described below: label meaning danger! Engines emit carbon monoxide; operate only in well-ventilated area. Read the operator’s manual. No spar...

  • Page 12: Safety Information

    Safety information g 7ai wc_si000088gb.Fm 10 caution! Lifting point when test button is lit, the isolation monitor has tripped. Stop the engine. Read the opera- tor’s manual for further information. Open main circuit breaker. Open the fuel flow valve. Open the choke. Close the choke. Label meaning.

  • Page 13: G 7Ai

    G 7ai safety information wc_si000088gb.Fm 11 push or turn engine switch to on position. Pull the rewind starter. Close main circuit breaker. Close the fuel flow valve. Push or turn engine switch to off position. Warning! Electric shock hazard. Read operator’s manual for instructions. A nameplate lis...

  • Page 14: Technical Data

    Technical data g 7ai wc_td000088gb.Fm 12 3. Technical data 3.1 generator item no. G 7ai 0009104 rev 105 and higher g 7ai 0009104 rev 104 and lower 0009105, 0009106, 0009107 generator continuous output 3ø kva (kw) 1ø kva/kw 5,4 (4,3) 5,0 7,0 (5,6) 4,9 type dual voltage, brush-type system ac voltages ...

  • Page 15: G 7Ai

    G 7ai technical data wc_td000088gb.Fm 13 3.2 engine item no. G 7ai 0009104 rev 105 and higher g 7ai 0009104 rev 104 and lower 0009105, 0009106, 0009107 engine engine make honda engine model gx 390 ui gx 390 k1 rated power kw 8.2 spark plug ngk bpr 6es electrode gap mm 0.7 - 0.8 engine speed - full l...

  • Page 16: Technical Data

    Technical data g 7ai wc_td000088gb.Fm 14 3.3 sound specifications the required sound specification, paragraph 1.7.4.F of 89/392/eec machinery directive, is: • 0009104 revision 105 and higher - guaranteed sound power level (l wa ) = 97 db(a). • 0009104 revision 104 and lower, 0009105, 009106, 0009108...

  • Page 17: G 7Ai

    G 7ai operation wc_tx000235gb.Fm 15 4. Operation 4.1 application and power requirements this generator is designed to operate single-phase 50 hz appliances running at 230 vac and three-phase 50 hz appliances at 400 vac. Both single and three phase sides of the generator can be used at the same time....

  • Page 18: Operation

    Operation g 7ai wc_tx000235gb.Fm 16 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 requi...

  • Page 19: G 7Ai

    G 7ai operation wc_tx000235gb.Fm 17 4.3 outdoor installation place the generator in an area where it will not be exposed to rain, snow, or direct sunlight. Make sure it is positioned on firm, level ground, so it will not slide or shift. Position the engine exhaust away from areas where people may be...

  • Page 20: Operation

    Operation g 7ai wc_tx000235gb.Fm 18 4.5 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 r...

  • Page 21: G 7Ai

    G 7ai operation wc_tx000235gb.Fm 19 4.6 use of extension cords when a long extension cord is used to connect an appliance or tool to the generator, a voltage loss occurs—the longer the cord, the greater the voltage loss. This results in less voltage being supplied to the appliance or tool and increa...

  • Page 22: Operation

    Operation g 7ai wc_tx000235gb.Fm 20 minimum extension cord size 230v minimum extension cord size 400v volts total length of cord in meters 230 v 0 - 30 30 - 60 amp rating cross sectional area of wire in mm 2 2 0.75 1.5 4 1.5 2.5 6 1.5 4 8 2.5 4 10 2.5 6 15 4 10 20 6 10 25 6 16 30 10 16 400 v amp rat...

  • Page 23: G 7Ai

    G 7ai operation wc_tx000235gb.Fm 21 10 6 4 2.5 1.5 0 1000 2000 3000 4000 5000 6000 wc_gr001081 a x m mm 2 16 25 1~ 23 0v 50 hz 3~ 40 0v 50 hz.

  • Page 24: Operation

    Operation g 7ai wc_tx000235gb.Fm 22 4.7 isolation monitor see graphic: wc_gr000274 generator is equipped with an isolation monitor. The isolation monitor consists of a sensing module (a), a test button with light (b), a relay (c), and a breaker for each phase and neutral (d1-d4). The relay and the b...

  • Page 25: G 7Ai

    G 7ai operation wc_tx000235gb.Fm 23 4.8 control panel see graphic: wc_gr000273, wc_gr001082 the generator is protected by a 16 amp circuit breaker (a) located on the control panel. The circuit breaker protects the generator from severe overloads or short circuits. If the circuit breaker opens, turn ...

  • Page 26: Operation

    Operation g 7ai wc_tx000235gb.Fm 24 4.9 before starting 4.9.1 read and understand safety and operating instructions at beginning of this manual. 4.9.2 read and understand the meanings of all warning and operating labels. 4.9.3 check: • oil level in engine. • fuel level. • condition of air cleaner. •...

  • Page 27: G 7Ai

    G 7ai operation wc_tx000235gb.Fm 25 4.11 to stop see graphic: wc_gr000665, wc_gr000274 4.11.1 turn off and disconnect all tools and appliances attached to the generator. 4.11.2 place main circuit breaker in open position (e2). 4.11.3 turn engine switch to “off” (c2). 4.11.4 close fuel valve by movin...

  • Page 28: Maintenance

    Maintenance g 7ai wc_tx000236gb.Fm 26 5. Maintenance 5.1 engine maintenance the chart below lists basic machine and engine maintenance. Refer to the engine manufacturer’s operator’s manual for additional information on engine maintenance. 5.2 periodic maintenance schedule daily before starting after...

  • Page 29: G 7Ai

    G 7ai maintenance wc_tx000236gb.Fm 27 5.3 engine oil see graphic: wc_gr000022 5.3.1 drain the oil while the engine is still warm. 5.3.2 remove the oil filler plug (a) and the drain plug (b) to drain the oil. Note: in the interests of environmental protection, place a plastic sheet and a container un...

  • Page 30: Maintenance

    Maintenance g 7ai wc_tx000236gb.Fm 28 5.4 air cleaner see graphic: wc_gr000025 the engine is equipped with a dual element air cleaner. Service air cleaner frequently to prevent carburetor malfunction. Caution: never run engine without air cleaner. Severe engine damage will occur. Never use gasoline ...

  • Page 31: G 7Ai

    G 7ai maintenance wc_tx000236gb.Fm 29 5.5 spark plug see graphic: wc_gr000028 clean or replace the spark plug as needed to ensure proper operation. Refer to the engine owner’s manual. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch th...

  • Page 32: Maintenance

    Maintenance g 7ai wc_tx000236gb.Fm 30 5.6 cleaning the sediment cup see graphic: wc_gr000029 5.6.1 turn the fuel valve off. 5.6.2 remove the sediment cup (a) and the o-ring (b). 5.6.3 wash both thoroughly in a nonflammable solvent. Dry and reinstall them. 5.6.4 turn the fuel valve on and check for l...

  • Page 33: G 7Ai

    G 7ai maintenance wc_tx000236gb.Fm 31 5.7 carburetor adjustment see graphic: wc_gr001061 the pilot screw (a) is fitted with a limiter capto prevent excessive enrichment of the air-fuel mixture in order to comply with emission regulations. The mixture is set at the factory and no adjustment should be...

  • Page 34: Maintenance

    Maintenance g 7ai wc_tx000236gb.Fm 32 5.8 engine speed see graphic: wc_gr000114 adjust engine to the no load or idle speed per the technical data. 5.8.1 start the engine and allow it to warm up to normal operating temperature. 5.8.2 turn the throttle stop screw (a) in to increase speed, out to decre...

  • Page 35: G 7Ai

    G 7ai maintenance wc_tx000236gb.Fm 33 5.9 storage before storing the generator for a long period of time: 5.9.1 close the fuel valve and remove and empty the sediment cup or fuel strainer. 5.9.2 disconnect the fuel line from the carburetor. Place open end of fuel line into a suitable container and o...

  • Page 36: Maintenance

    Maintenance g 7ai wc_tx000236gb.Fm 34 5.11 troubleshooting 5.12 wire colors problem / symptom reason / remedy if engine doesn't start, check that: • engine switch is on "start". • fuel valve on engine is open. • fuel tank has fuel. • choke lever is in correct position. Choke should be closed when st...

  • Page 37: G 7Ai

    G 7ai maintenance wc_tx000236gb.Fm 35 5.13 engine wiring schematic ref. Description ref. Description 1. Oil level switch 3. Ignition switch 2. Coil w c _ g r 0 0 0 4 0 7 o f f o n b b y b / r g !.

  • Page 38: Maintenance

    Maintenance g 7ai wc_tx000236gb.Fm 36 5.14 generator wiring schematic - schuko, french ref. Description ref. Description 1. Rotor winding 7. Filter (ris) 2. Automatic voltage regulator 8. Hour meter 3. Isolation monitor 9. Circuit breaker/trip relay 4. 250 volt/16 amp receptacle- french/schuko 10. T...

  • Page 39: G 7Ai

    G 7ai maintenance wc_tx000236gb.Fm 37 5.15 generator wiring schematic - cee ref. Description ref. Description 1. Rotor winding 6. Filter (ris) 2. Automatic voltage regulator 7. Circuit breaker/trip relay 3. Isolation monitor 8. Hour meter 4. 230 volt/16 amp receptacle cee 9. Test switch and light 5....

  • Page 40: Maintenance

    Maintenance g 7ai wc_tx000236gb.Fm 38 5.16 generator wiring schematic - swiss ref. Description ref. Description 1. Rotor winding 7. Filter (ris) 2. Automatic voltage regulator 8. Hour meter 3. Isolation monitor 9. Circuit breaker/trip relay 4. 230 volt/16 amp receptacle-swiss 10. Test switch and lig...

  • Page 41

    2008-ce-generators7ai_q.Fm william lahner dan domanski vice president of engineering manager, product engineering wacker neuson corporation date / datum / fecha / date ec declaration of conformity ce-konformitÄtserklÄrung declaraciÓn de conformidad de la ce dÉclaration de conformitÉ c.E. Wacker neus...

  • Page 42

    Wacker construction equipment ag · preußenstraße 41 · d-80809 münchen · tel.: +49-(0)89-3 54 02 - 0 · fax: +49 - (0)89-3 54 02-3 90 wacker corporation · p.O. Box 9007 · menomonee falls, wi 53052-9007 · tel. : (262) 255-0500 · fax: (262) 255-0550 · tel. : (800) 770-0957 wacker asia pacific operations...