Wacker Neuson GV 7003A User manual

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.: [phone]
Fax: [phone]
Translation of the original operator's manual in German

1Foreword
3100_0000_0002.fm
1Foreword
This operator's manual contains information and procedures for the safe opera-
tion 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 con-
sideration when this machine was designed. Nevertheless, improper use or in-
correct 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 2013Wacker Neuson Produktion GmbH & Co. KG
No part of this publication may be reproduced in any form or by any means, elec-
tronic or mechanical, including photocopying, without the expressed written per-
mission 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 stan-
dards.

2 Introduction
100_0000_0003.fm 4
2Introduction
2.1 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 dam-
age to equipment and exclude improper service.
Notes
Note: Complementary information will be displayed here.
DANGER
This warning notice indicates immediate hazards that result in serious injury or
even death.
XDanger 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.
XDanger can be avoided by the following the actions mentioned.
CAUTION
This warning notice indicates possible hazards that can result in minor injury.
XDanger can be avoided by the following the actions mentioned.
NOTICE
This warning notice indicates possible hazards that can result in material dam-
age.
XDanger can be avoided by the following the actions mentioned.

2 Introduction
5100_0000_0003.fm
Instructions
XThis symbol indicates there is something for you to do.
1. Numbered instructions indicate that you have to carry out something in a de-
fined sequence.
This symbol is used for lists.
2.2 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.

2 Introduction
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2.4 Identification of the machine
Nameplate data
The nameplate lists information that uniquely identifies your machine. This infor-
mation is needed to order spare parts and when requesting additional technical
information.
XEnter the information of your machine into the following table:
Item Designation Your information
1 Group and type
2 Construction year
3 Machine no.
4 Version no.
5 Item no.

Original-Konformitätserklärung
EG-Konformitätserklärung
Hersteller
Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München
Produkt
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
Produkt GV 7000A GV 7003A
Produkt-Art Generator
Produkt-Funktion Erzeugen von Strom
Artikel-Nummer 0009348 0009353 5100002155
Installierte Nutzleistung 5,47 kW 5,60 kW
Gemessener
Schallleistungspegel
97 dB(A)
Garantierter
Schallleistungspegel
97 dB(A)
Dr. Michael Fischer
Geschäftsführer Technik und Innovation
München, 01.02.2013

wc_bo5000187301_08TOC.fm 9
Table of ContentsGV 7000A / 7003A
Foreword 3
1 Safety Information 11
1.1 Signal Words Used in this Manual ..................................................... 11
1.2 Machine Description and Intended Use ............................................. 12
1.3 Safety Guidelines for Operating the Machine ..................................... 13
1.4 Operator Safety while Using Internal Combustion Engines ............... 16
1.5 Service Safety .................................................................................... 17
2 Labels 19
3 Lifting and Transporting 20
4 Operation 21
4.1 Preparing the Machine for First Use ................................................... 21
4.2 Power Requirements .......................................................................... 22
4.3 Installation .......................................................................................... 22
4.4 Generator Derating ............................................................................. 24
4.5 Grounding the Generator ................................................................... 25
4.6 Operating Heavy Loads ...................................................................... 25
4.7 Use of Extension Cords ...................................................................... 26
4.8 Control Panel ...................................................................................... 28
4.9 Before Starting ................................................................................... 30
4.10 Starting ............................................................................................... 30
4.11 Stopping ............................................................................................. 31
4.12 Emergency Shutdown Procedure ....................................................... 31

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Table of Contents GV 7000A / 7003A
5 Maintenance 32
5.1 Periodic Maintenance Schedule ..........................................................32
5.2 Engine Oil ............................................................................................33
5.3 Servicing the Air Cleaner .....................................................................34
5.4 Spark Plug ...........................................................................................35
5.5 Engine Speed ......................................................................................36
5.6 Long-Term Storage .............................................................................37
6 Basic Troubleshooting 38
7 Technical Data 39
8 Schematics 42
8.1 GV 7000A—Electrical Schematic ........................................................42
8.2 GV 7003A—Electrical Schematic ........................................................43

GV 7000A / 7003A Safety Information
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1 Safety Information
1.1 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.
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.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
fObey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
fTo 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.
fTo avoid possible death or serious injury from this type of hazard, obey all safety mes-
sages that follow this signal word.
CAUTION!
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
fTo avoid possible minor or moderate injury from this type of hazard, obey all safety mes-
sages that follow this signal word.

Safety Information GV 7000A / 7003A
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1.2 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

GV 7000A / 7003A Safety Information
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• 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
Connection requirements
The following are required when connecting the generator to a
building’s electrical system.
• 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.
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.
fNEVER 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.
fONLY use a generator outside and far away from windows, doors, and vents.
These openings can pull in generator exhaust.
fEven 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.
fIf 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 back-
feed into utility lines. This may result in electrocution, serious injury, or death to util-
ity workers!
fComply with the connection requirements described below.

Safety Information GV 7000A / 7003A
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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.
WARNING

GV 7000A / 7003A Safety Information
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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.
• 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.

Safety Information GV 7000A / 7003A
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1.4 Operator Safety while Using Internal Combustion Engines
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.
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.
fRead and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
fCarbon 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.

GV 7000A / 7003A Safety Information
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1.5 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 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:
• 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.
WARNING

Safety Information GV 7000A / 7003A
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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.

2Safety and information labels
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2Safety 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 Label Description
1 Guaranteed sound power level.
2DANGER!
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.

Lifting and Transporting GV 7000A / 7003A
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3 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.