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Summary of Contents for Wacker Neuson G 7Ai
- Page 1 0152817en 0309 Generator G 7Ai OPERATOR’S MANUAL...
- 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.
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Page 3: Table Of Contents
G 7Ai Table of Contents Foreword Safety Information Operating Safety .................. 5 Operator Safety while using Internal Combustion Engines ....6 Service Safety ..................7 Label Locations ..................8 Safety and Operating Labels ..............9 Technical Data Generator ................... 12 Engine .................... - Page 4 Table of Contents G 7Ai Maintenance Engine Maintenance ................26 Periodic Maintenance Schedule ............26 Engine Oil ....................27 Air Cleaner ..................28 Spark Plug ...................29 Cleaning the Sediment Cup ..............30 Carburetor Adjustment ................31 Engine Speed ..................32 Storage ....................33 5.10 Transport .....................33 5.11 Troubleshooting ...................34 5.12...
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Page 5: Foreword
CALIFORNIA Proposition 65 Warning: Engine exhaust, some of its constituents, and certain vehicle components, contain or emit chemicals known to the State of WARNING California to cause cancer and birth defects or other reproductive harm. Foreword This manual provides information and procedures to safely operate and maintain this Wacker model. -
Page 6: Safety Information
Safety Information G 7Ai Safety Information This manual contains DANGER, WARNING, CAUTION, and NOTE callouts which must be followed to reduce the possibility of personal injury, damage to the equipment, or improper service. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. -
Page 7: Operating Safety
G 7Ai Safety Information Operating Safety BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWER DISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY OR DEATH TO UTILITY WORKERS! DANGER Improper connection of generator to a building's electrical system can allow electrical current from the generator to backfeed into utility lines. -
Page 8: Operator Safety While Using Internal Combustion Engines
Safety Information G 7Ai 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 operate generator firm, noncombustible, level surface. -
Page 9: Service Safety
G 7Ai Safety Information Service Safety Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly over a long period of time, periodic maintenance and occasional repairs are necessary. If WARNING the generator is experiencing problems or is being serviced, attach a “DO NOT START”... -
Page 10: Label Locations
Safety Information G 7Ai Label Locations DANGER GEFAHR STOP PELIGRO DANGER wc_si000088gb.fm... -
Page 11: Safety And Operating Labels
G 7Ai Safety Information Safety and Operating Labels Wacker machines use international pictorial labels where needed. These labels are described below: Label Meaning DANGER GEFAHR STOP PELIGRO DANGER DANGER! Engines emit carbon monoxide; operate only in well-ventilated area. Read the Operator’s Manual. - Page 12 Safety Information G 7Ai Label Meaning 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.
- Page 13 G 7Ai Safety Information Label Meaning 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.
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Page 14: Technical Data
Technical Data G 7Ai Technical Data Generator Item No. G 7AI G 7AI 0009104 Rev 105 and 0009104 Rev 104 and higher lower 0009105, 0009106, 0009107 Generator Continuous Output 3ø kVA (kW) 5,4 (4,3) 7,0 (5,6) 1ø kVA/kW Type Dual voltage, brush-type system... -
Page 15: Engine
G 7Ai Technical Data Engine Item No. G 7AI G 7AI 0009104 Rev 105 and 0009104 Rev 104 and higher lower 0009105, 0009106, 0009107 Engine Engine Make Honda Engine Model GX 390 UI GX 390 K1 Rated Power Spark Plug... -
Page 16: Sound Specifications
Technical Data G 7Ai 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 ) = 97 dB(A). • 0009104 Revision 104 and lower, 0009105, 009106, 0009108 - guar- anteed sound power level (L ) = 99 dB(A). -
Page 17: Operation
G 7Ai Operation Operation 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: Indoor Installation
Operation G 7Ai 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 watt- age to start. -
Page 19: Outdoor Installation
G 7Ai Operation Outdoor Installation Place the generator in an area where it will not be exposed to rain, snow, or direct sunlight. Make sure it is positioned on firm, level ground, so it will not slide or shift. Position the engine exhaust away from areas where people may be present. -
Page 20: Generator Derating
Operation G 7Ai 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. -
Page 21: Use Of Extension Cords
G 7Ai Operation Use of Extension Cords When a long extension cord is used to connect an appliance or tool to the generator, a voltage loss occurs—the longer the cord, the greater the voltage loss. This results in less voltage being supplied to the appliance or tool and increases the amount of current draw or reduces performance. - Page 22 Operation G 7Ai Minimum Extension Cord Size 230V Volts Total length of cord in meters 230 V 0 - 30 30 - 60 Amp Rating Cross sectional area of wire in mm 0.75 Minimum Extension Cord Size 400V 400 V...
- Page 23 G 7Ai Operation 1000 2000 3000 4000 5000 6000 A x m wc_gr001081 wc_tx000235gb.fm...
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Page 24: Isolation Monitor
Operation G 7Ai 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 breakers are mechanically ganged together and operate as the main circuit breaker. -
Page 25: Control Panel
G 7Ai Operation 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 the engine off immediately and determine the cause before restarting. -
Page 26: Before Starting
4.10.5 Open choke as engine warms (b2). 4.10.6 Place main circuit breaker in closed position (e1). Allow the engine to warm up for a few minutes before attaching loads. On models G 7Ai check function of the Isolation Monitor. See Section Isolation Monitor. -
Page 27: To Stop
G 7Ai Operation 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 moving lever to the left (a2). -
Page 28: Maintenance
Maintenance G 7Ai Maintenance Engine Maintenance The chart below lists basic machine and engine maintenance. Refer to engine manufacturer’s Operator’s Manual additional information on engine maintenance. Periodic Maintenance Schedule Daily After Every Every Every before first starting 20 hrs. hrs. -
Page 29: Engine Oil
G 7Ai Maintenance Engine Oil See Graphic: wc_gr000022 5.3.1 Drain the oil while the engine is still warm. 5.3.2 Remove the oil filler plug (a) and the drain plug (b) to drain the oil. Note: In the interests of environmental protection, place a plastic sheet and a container under the machine to collect any liquid that drains off. -
Page 30: Air Cleaner
Maintenance G 7Ai 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 or other types of low flash point solvents for cleaning the air cleaner. -
Page 31: Spark Plug
G 7Ai Maintenance Spark Plug See Graphic: wc_gr000028 Clean or replace the spark plug as needed to ensure proper operation. Refer to the engine owner’s manual. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Do not touch the muffler while it is hot. -
Page 32: Cleaning The Sediment Cup
Maintenance G 7Ai 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 leaks. -
Page 33: Carburetor Adjustment
G 7Ai Maintenance Carburetor Adjustment See Graphic: wc_gr001061 The pilot screw (a) is fitted with a limiter cap to 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 necessary. -
Page 34: Engine Speed
Maintenance G 7Ai 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 decrease speed. -
Page 35: Storage
G 7Ai Maintenance 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 open fuel valve to drain fuel from tank. -
Page 36: Troubleshooting
Maintenance G 7Ai 5.11 Troubleshooting Problem / Symptom Reason / Remedy If engine doesn't start, check • Engine switch is on "Start". that: • Fuel valve on engine is open. • Fuel tank has fuel. • Choke lever is in correct position. Choke should be closed when starting a cold engine. -
Page 37: Engine Wiring Schematic
G 7Ai Maintenance 5.13 Engine Wiring Schematic O F F B / R w c _ g r 0 0 0 4 0 7 Ref. Description Ref. Description Oil level switch Ignition switch Coil wc_tx000236gb.fm... -
Page 38: Generator Wiring Schematic - Schuko, French
Maintenance G 7Ai 5.14 Generator Wiring Schematic - Schuko, French Ref. Description Ref. Description Rotor winding Filter (RIS) Automatic voltage regulator Hour Meter Isolation Monitor Circuit Breaker/Trip Relay 250 volt/16 Amp receptacle- Test Switch and Light French/Schuko 230 volt/16 Amp receptacle CEE... -
Page 39: Generator Wiring Schematic - Cee
G 7Ai Maintenance 5.15 Generator Wiring Schematic - CEE Ref. Description Ref. Description Rotor winding Filter (RIS) Automatic voltage regulator Circuit Breaker/Trip Relay Isolation Monitor Hour Meter 230 volt/16 Amp receptacle CEE Test switch and light 400 volt/16 Amp receptacle-3... -
Page 40: Generator Wiring Schematic - Swiss
Maintenance G 7Ai 5.16 Generator Wiring Schematic - Swiss Ref. Description Ref. Description Rotor winding Filter (RIS) Automatic voltage regulator Hour Meter Isolation Monitor Circuit Breaker/Trip Relay 230 volt/16 Amp receptacle-Swiss Test switch and light 230 volt/16 Amp receptacle CEE... -
Page 41: Ec Declaration Of Conformity
EC DECLARATION OF CONFORMITY CE-KONFORMITÄTSERKLÄRUNG DECLARACIÓN DE CONFORMIDAD DE LA CE DÉCLARATION DE CONFORMITÉ C.E. WACKER NEUSON CORPORATION, N92 W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA WACKER CONSTRUCTION EQUIPMENT AG AUTHORIZED REPRESENTATIVE IN THE EUROPEAN UNION BEVOLLMÄCHTIGTER VERTRETER FÜR DIE EUROPÄISCHE GEMEINSCHAFT Preußenstraße 41... - 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 ·...
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