Generator

GS 12Ai

OPERATOR’S MANUAL

0170874en 002

1208

0 1 7 0 8 7 4 E N

DANGER

CARBON MONOXIDEUsing 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.

• NEVER use a generator inside homes, garages, crawlspaces, or other partly enclosed areas. Deadly levels of carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply enough fresh air.

• ONLY use a generator outside and far away from windows, doors, and vents. These openings can pull in generator exhaust.

Even when you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or battery-backup CO alarm in the home.

If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air RIGHT AWAY. See a doctor. You could have carbon monoxide poison.

CALIFORNIAProposition 65 Warning:

Engine exhaust, some of its constituents, and certain vehiclecomponents, contain or emit chemicals known to the State ofCalifornia to cause cancer and birth defects or other reproductiveharm.

ForewordThis manual provides information and procedures to safely operateand maintain this Wacker Neuson model. For your own safety andprotection from injury, carefully read, understand and observe thesafety instructions described in this manual.

Keep this manual or a copy of it with the machine. If you lose thismanual or need an additional copy, please contact Wacker NeusonCorporation. This machine is built with user safety in mind; however,it can present hazards if improperly operated and serviced. Followoperating instructions carefully! If you have questions about operatingor servicing this equipment, please contact Wacker NeusonCorporation.

The information contained in this manual was based on machines inproduction at the time of publication. Wacker Neuson Corporationreserves the right to change any portion of this information withoutnotice.

All rights, especially copying and distribution rights, are reserved.

Copyright 2008 by Wacker Neuson Corporation.

No part of this publication may be reproduced in any form or by anymeans, electronic or mechanical, including photocopying, withoutexpress written permission from Wacker Neuson Corporation.

Any type of reproduction or distribution not authorized by WackerNeuson Corporation represents an infringement of valid copyrightsand will be prosecuted. We expressly reserve the right to maketechnical modifications, even without due notice, which aim atimproving our machines or their safety standards.

WARNING

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GS 12Ai Table of Contents

1. Foreword 3

2. Safety Information 7

2.1 Operating Safety .................................................................................. 82.2 Operator Safety while using Internal Combustion Engines .................. 92.3 Service Safety .................................................................................... 102.4 Label Locations .................................................................................. 112.5 Safety and Operating Labels .............................................................. 12

3. Operation 14

3.1 Application and Power Requirements ................................................ 143.2 Installation .......................................................................................... 153.3 Generator Derating ............................................................................. 163.4 Use of Extension Cords ...................................................................... 173.5 Isolation Monitor ................................................................................. 203.6 Control Panel ...................................................................................... 213.7 Before Starting ................................................................................... 223.8 To Run ................................................................................................ 223.9 To Stop ............................................................................................... 23

4. Maintenance 24

4.1 Engine Maintenance ........................................................................... 244.2 Periodic Maintenance Schedule ......................................................... 244.3 Engine Oil ........................................................................................... 254.4 Air Cleaner ......................................................................................... 264.5 Spark Plug .......................................................................................... 274.6 Fuel Filter ........................................................................................... 284.7 Engine Speed ..................................................................................... 284.8 Storage ............................................................................................... 294.9 Transport ............................................................................................ 294.10 Troubleshooting .................................................................................. 304.11 Wire Colors ......................................................................................... 304.12 Engine Wiring Schematic ................................................................... 314.13 Generator Wiring Schematic .............................................................. 32

5

Table of Contents GS 12Ai

5. Technical Data 33

5.1 Generator ............................................................................................335.2 Engine .................................................................................................345.3 Sound Specifications ...........................................................................35

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GS 12Ai Safety Information

1. Safety Information

This manual contains DANGER, WARNING, CAUTION, NOTICE andNOTE callouts which must be followed to reduce the possibility ofpersonal injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potentialpersonal injury hazards. Obey all safety messages that follow thissymbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, willresult in death or serious injury.

WARNING indicates a hazardous situation which, if not avoided, couldresult in death or serious injury.

CAUTION indicates a hazardous situation which, if not avoided, couldresult in minor or moderate injury.

NOTICE: Used without the safety alert symbol, NOTICE indicates asituation which, if not avoided, could result in property damage.

Note: Contains additional information important to a procedure.

DANGER

WARNING

CAUTION

7

Safety Information GS 12Ai

1.1 Operating Safety

BACKFEED FROM THE GENERATOR INTO THE PUBLIC POWERDISTRIBUTION SYSTEM CAN CAUSE SERIOUS INJURY ORDEATH TO UTILITY WORKERS!Improper connection of generator to a building’s electrical system canallow electrical current from the generator to backfeed into utility lines.This may result in electrocution of utility workers, fire, or explosion.Connections to a building’s electrical system must be made by aqualified electrician and comply with all applicable laws and electricalcodes.If connected to a building’s electrical system the generator must meetthe power, voltage, and frequency requirements of the equipment inthe building. Differences in power, voltage, and frequencyrequirements may exist and improper connection may lead toequipment damage, fire, and personal injury or death. Familiarity and proper training are required for the safe operation of themachine. Machines operated improperly or by untrained personnelcan be hazardous. Read the operating instructions contained in boththis manual and the engine manual and familiarize yourself with thelocation and proper use of all controls. Inexperienced operators shouldreceive instruction from someone familiar with the machine beforebeing allowed to operate it.

1.1.1 NEVER operate the generator when open containers of fuel, paint, orother flammable liquids are near.

1.1.2 NEVER operate the generator, or tools attached to the generator, withwet hands.

1.1.3 NEVER use worn electrical cords. Severe electrical shock andequipment damage may result.

1.1.4 NEVER run the electrical cords under the generator, or over vibratingor hot parts.

1.1.5 NEVER enclose or cover the generator when it is in use or when it ishot.

1.1.6 NEVER overload the generator. The total amperage of the tools andequipment attached to the generator must not exceed the load ratingof the generator.

1.1.7 NEVER operate the machine in snow, rain, or standing water.

1.1.8 NEVER allow untrained personnel to operate or service the generator.The generator set should be set up by a certified electrician.

1.1.9 NEVER connect generators with isolation monitors in parallel. Thiswould affect the operation of the isolation monitor.

DANGER

8

GS 12Ai Safety Information

1.1.10 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.1.1.11 ALWAYS position and operate the generator on a firm,

noncombustible, level surface.

1.1.12 ALWAYS transport the generator in an upright position.

1.1.13 ALWAYS keep the machine at least one meter (three feet) away fromstructures, buildings, and other equipment during use.

1.1.14 ALWAYS keep the area immediately surrounding and underneath themachine clean, neat, and free of debris and combustible materials.Make sure that the area overhead is clear of debris that could fall ontoor into the machine or exhaust compartment.

1.1.15 ALWAYS remove all tools, cords, and other loose items from thegenerator before starting it.

1.2 Operator Safety while using Internal Combustion Engines

Internal combustion engines present special hazards during operationand fueling. Read and follow the warning instructions in the engineowner’s manual and the safety guidelines below. Failure to follow thewarnings and safety standards could result in severe injury or death.Using a generator indoors CAN KILL YOU IN MINUTES. Generatorexhaust contains carbon monoxide. This is a poison you cannot see orsmell. NEVER use this generator inside a home or garage, EVEN IFdoors and windows are open. Only use this generator OUTSIDE andfar away from windows, doors, and vents.

1.2.1 Do not smoke while operating the machine.1.2.2 Do not smoke when refueling the engine.1.2.3 Do not refuel a hot or running engine.1.2.4 Do not refuel the engine near an open flame.1.2.5 Do not spill fuel when refueling the engine.1.2.6 Do not run the engine near open flames.1.2.7 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 beforestarting.

1.2.8 Refill the fuel tank in a well-ventilated area.1.2.9 Replace the fuel tank cap after refueling.1.2.10 ALWAYS check the fuel lines and the fuel tank for leaks and cracks

before starting the engine. Do not run the machine if fuel leaks arepresent or the fuel lines are loose.

WARNING

DANGER

9

Safety Information GS 12Ai

1.3 Service Safety

Poorly maintained equipment can become a safety hazard! In orderfor the equipment to operate safely and properly over a long period oftime, periodic maintenance and occasional repairs are necessary. Ifthe generator is experiencing problems or is being serviced, attach a“DO NOT START” sign to the control panel to notify other people of itscondition.

1.3.1 Do not use gasoline or other types of fuels or flammable solvents toclean parts, especially in enclosed areas. Fumes from fuels andsolvents can become explosive.

1.3.2 DO NOT attempt to clean or service the machine while it is running.

1.3.3 Do not modify the machine without the express written approval of themanufacturer.

1.3.4 DO NOT allow water to accumulate around the base of the machine.If water is present, move the machine and allow the machine to drybefore servicing.

1.3.5 DO NOT service the machine if your clothing or skin is wet.

1.3.6 DO NOT allow untrained personnel to service this equipment. Onlytrained electrical technicians should be allowed to service the electricalcomponents of this equipment.

1.3.7 Keep the machine clean and labels legible. Replace all missing andhard-to-read labels. Labels provide important operating instructionsand warn of dangers and hazards.

1.3.8 ALWAYS replace the safety devices and guards after repairs andmaintenance.

1.3.9 ALWAYS let the engine cool before transporting or servicing it.

1.3.10 ALWAYS keep hands, feet, and loose clothing away from the movingparts on the generator and engine.

1.3.11 ALWAYS turn the engine off before servicing the machine. If theengine has electric start, disconnect the negative terminal on thebattery before servicing the machine.

1.3.12 ALWAYS keep the fuel lines in good condition and properly connected.Leaking fuel and fumes are extremely explosive.

WARNING

10

GS 12Ai Safety Information

1.4 Label Locations

OFF

ON

PETROL

GA

SO

LIN

A

ISS

INC

I

BENZIN

11

Safety Information GS 12Ai

1.5 Safety and Operating Labels

Wacker Neuson machines use international pictorial labels whereneeded. These labels are described below:

Label Meaning

DANGER!Engines emit carbon monoxide; operate only in well-ventilated area. Read the Operator’s Manual.No sparks, flames, or burning objects near the machine. Shut off the engine before refueling.Gasoline

WARNING! Hot surface!

Potential Earth - Hook up cable from ground-ing rod to this point.

WARNING! Electric shock will cause serious injury or death.

Close the fuel flow valve.

Open the fuel flow valve.

PETROL

GA

SO

LIN

A

ISS

INC

I

BENZIN

OFF

ON

12

GS 12Ai Safety Information

Guaranteed sound power level in dB(A).

A nameplate listing the model number, item number, revision number, and serial number is attached to each unit. Please record the infor-mation found on this plate so it will be avail-able should the nameplate become lost or damaged. When ordering parts or requesting service information, you will always be asked to specify the model number, item number, revision number, and serial number of the unit.

Label Meaning

13

Operation GS 12Ai

2. Operation

2.1 Application and Power Requirements

This generator is designed to operate single-phase 50 Hz appliancesrunning 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 thesame time.NOTICE: Do not exceed the power output of the generator. Damageto tools or generator will occur. See Technical Data.Check the nameplate or label provided on tools and appliances tomake sure their power requirements are met by the power output of thegenerator. If the wattage is not given for a particular tool or appliance,contact the tool manufacturer for wattage requirements.Some appliances and tools require a surge of current when starting.This means that the amount of power needed to initially start theequipment is larger than the power required to keep it running. Thegenerator must be capable of supplying this "surge" current. Othertypes of appliances require more power than is actually stated on theirnameplate.The information in “Approximate Starting Power Requirements” isoffered only as a general guideline to help you determine powerrequirements for different types of equipment. Check with your nearestWacker Neuson dealer, or contact the manufacturer or dealer of thetool or appliance, if you have questions regarding power requirements.NOTICE: DO NOT exceed the rated current limit of any receptacle.NOTICE: If a tool or appliance does not reach full speed within a fewseconds after it is switched on, turn it off immediately to avoid damage.

14

GS 12Ai Operation

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.

• Electrical motors and many types of electrical tools often require a large starting current. The amount of starting current depends on the type of motor and its use.

• Most electrical tools require 1.2–3 times their stated wattage for start-ing.

• Loads such as submersible pumps and air compressors require a very large force to start. They need as much as 3–5 times the wattage stated on the nameplate in order to start.

If the wattage is not given for a particular tool or appliance, it can becalculated by multiplying its voltage and amperage requirements:Single Phase: VOLTS x AMPS = WATTSThree Phase: VOLTS x AMPS x 1.732 x 0.8 = WATTS

2.2 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, levelground, so it will not slide or shift. Position the engine exhaust awayfrom areas where people may be present.The surrounding area must be free from water and moisture. Allcomponents must be protected from excessive moisture. Using a generator indoors CAN KILL YOU IN MINUTES. Generatorexhaust contains carbon monoxide. This is a poison you cannot see orsmell. NEVER use this generator inside a home or garage, EVEN IFdoors and windows are open. Only use this generator OUTSIDE andfar away from windows, doors, and vents.NEVER install a generator in an enclosed area such as a tunnel or atrench. Using a generator in a tunnel or a trench CAN KILL YOU INMINUTES. Generator exhaust contains carbon monoxide. This is apoison you cannot see or smell. NEVER use this generator inside atunnel or a trench.

DANGER

DANGERDANGER

15

Operation GS 12Ai

2.3 Generator Derating

All generators are subject to derating for altitude and temperature.Internal combustion engines, unless modified, run less efficiently athigher altitudes due to the reduction of air pressure. This translatesinto a lack of power and thus reduction in generator output.Temperature affects both engine and generator performance. Astemperature increases, an engine will run less efficiently and moreresistance will be found in electrical components. Therefore, as thetemperature increases, the output of the generator decreases. Altitudealso affects the cooling capacity of air—the higher the altitude the lessdense the air is and thus the lower its ability to transfer heat.For every increase in altitude of 500 m (1650 ft.) above 1000 m (3300ft.), the output of the generator will be reduced by 3%. For everyincrease of 5° C (9° F) in ambient temperature above 40° C (104° F),the output of the generator will be reduced by 3%. Use the tablesshown for altitude and temperature deration factors. It may benecessary to consider both altitude and ambient temperature derationfactors to determine true generator output.

Ambient Temp.°C (°F) Derate Factor

45 (113) 3 % 0.97

50 (122) 6 % 0.94

55 (131) 9 % 0.91

60 (140) 12 % 0.88

Altitudem (ft.) Derate Factor

1500 (4900) 3 % 0.97

2000 (6600) 6 % 0.94

2500 (8200) 9 % 0.91

3000 (9900) 12 % 0.88

3500 (11500) 15 % 0.85

4000 (13100) 18 % 0.82

16

GS 12Ai Operation

2.4 Use of Extension Cords

When a long extension cord is used to connect an appliance or tool tothe generator, a voltage loss occurs—the longer the cord, the greaterthe voltage loss. This results in less voltage being supplied to theappliance or tool and increases the amount of current draw or reducesperformance. A cord with a larger cross section will reduce the voltageloss. NOTICE: Operating equipment at low voltage can cause it to overheat.Use only tough rubber-sheathed cable in accordance with IEC 245-4.Damaged cords can cause electric shock. Electric shock can causeserious injury or death. DO NOT use worn, bare, or frayed cords.Replace damaged cords immediately.Do not exceed the rating of the cord.Contact the cord manufacturer if in doubt about cord use.Choose the cord size from the Minimum Extension Cord Size Table orcalculate minimum cord size using the Minimum Extension Cord SizeGraph. The X axis of the graph represents A x m (Ampere x meter)values. The Y axis represents wire size in mm2. Multiply the operatingcurrent for the load in amps (A) by the desired extension cord length inmeters (m). Find the result along the X axis. Move up the graph untilyou reach the appropriate sloped line for your application. Move to theY axis; this is the recommended minimum cord size. Example:For a 3-phase, 400V application, if the operating current for the load is15 A, and the desired extension cord length is 100 m, then: 15 A x 100 m = 1500 A x m.1500 A x m = 2.5 mm2.

WARNING

17

Operation GS 12Ai

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 mm2

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 Rating Diameter of cord, mm2 Maximum Fuse

15 1 10

18 1.5 10

26 2.5 20

34 4 25

44 6 35

61 10 50

82 16 63

108 25 80

18

GS 12Ai Operation

10

6

4

2.5

1.5

0 1000 2000 3000 4000 5000 6000

A x m

mm2

16

25

1~ 230V 50 Hz

3~ 400V 50 Hz

19

Operation GS 12Ai

2.5 Isolation Monitor

Generator is equipped with an Isolation Monitor. The Isolation Monitorconsists 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 andthe breakers are mechanically ganged together and operate as themain circuit breaker. The Isolation Monitor protects the operator froma ground fault by sensing a resistance change, as in a short to ground,on the output of the generator. When the Isolation Monitor senses aresistance change, it lights the TEST button and it causes the relay toopen, which mechanically trips the main circuit breaker. The IsolationMonitor cannot be reset with the generator running. Before themain circuit breaker can be closed, the generator must first be shutdown, the fault cleared, and the generator restarted.To test the Isolation Monitor:Start the generator. Place the main circuit breaker in the closedposition (e1). Push the TEST button (b). The TEST button will light up,and the main circuit breaker will move to the open position (e2). Poweris now off at the receptacles. If the breaker does not open, the IsolationMonitor is not working. Do not use the generator until the problem canbe corrected. To restore power to the receptacles, shut down thegenerator, restart it, and place the circuit breaker in the closed position(e1).The main circuit breaker is current-operated and shuts off the power tothe receptacles when an overcurrent occurs that is greater than whatthe breaker is rated for.If the circuit breaker lever opens during operation, stop the generatorand check the generator and any equipment it was powering fordefects. Repair all defects before operating the generator.

20

GS 12Ai Operation

2.6 Control Panel

The generator is protected by a 16 amp circuit breaker (a) located onthe control panel. The circuit breaker protects the generator from severe overloads orshort circuits. If the circuit breaker opens, turn the engine offimmediately and determine the cause before restarting. Check theappliances and tools attached to the generator for defects and makesure their power requirements do not exceed the power rating of thegenerator or the current limit of the receptacles. When the circuit breaker opens, the breaker lever will snap down. Toreset circuit breaker, lift lever up. The generator has following type of receptacles:Schuko (c1): Two 250 volt, IP54 (c), one 230 volt, IP44 CEE (d), andone 400 volt, 3-phase 5 pin receptacle IP54 CEE (b).CEE (c2): Three 230 volt CEE (c, d), and one 400 volt 5 pin receptacleCEE (b).Note: Enlargements of receptacles show protective covers removedfor identification purposes only. Never remove protective covers.

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21

Operation GS 12Ai

2.7 Before Starting

2.7.1 Read and understand safety and operating instructions at beginning ofthis manual.

2.7.2 Read and understand the meanings of all warning and operatinglabels.

2.7.3 Make sure that a battery has been installed. See Technical Data.

2.7.4 The generator is shipped and delivered dry (without battery acid). If thegenerator is being run for the first time, fill the battery cells with acid.

2.7.5 Check:

• oil level in engine

• fuel level.

• condition of air cleaner

• tightness of external fasteners

• condition of fuel lines

• battery acid level—add distilled water if necessary

2.8 To Run

2.8.1 Disconnect all loads from the generator and place main circuit breakerlever in open position (e2).

2.8.2 Open fuel valve.

2.8.3 If engine is cold, move choke lever to closed position (a1). If engine ishot, set choke to open position (a2).

2.8.4 Turn key switch to the start position (b3) and hold until engine starts.

NOTICE: Do not crank engine longer than 15 seconds at a time.Extended cranking can damage starter motor.Leave key in run position (b2) while engine is running.Note: Turn the keyswitch to the OFF position when the engine is notrunning. Leaving the key in the RUN position with the engine off willdrain the battery.

Note: The engine is equipped with a low oil protection system. If the oillevel is low, the engine will not start. Check engine oil level if enginedoes not start.

2.8.5 Open choke as engine warms (a2).2.8.6 Place main circuit breaker in closed position (e1). Allow the engine to

warm up for a few minutes before attaching loads. On models GS 12Aicheck function of the Isolation Monitor. See Section Isolation Monitor.

22

GS 12Ai Operation

2.9 To Stop

2.9.1 Turn off and disconnect all tools and appliances attached to thegenerator.

2.9.2 Place main circuit breaker in open position (e2).2.9.3 Turn engine switch to “OFF” (b1). 2.9.4 Turn fuel valve off.

Note: To stop engine quickly in an emergency, turn engine switch to"OFF".

23

Maintenance GS 12Ai

3. Maintenance

3.1 Engine Maintenance

The chart below lists basic machine and engine maintenance. Refer toyour engine operator’s manual for additional information on enginemaintenance.

3.2 Periodic Maintenance Schedule

* Service more frequently in dusty conditions

Dailybefore

starting

Afterfirst

20 hrs.

Every50

hrs.

Every100 hrs.

Every year or 300 hrs.

Check fuel level.

Check engine oil level.

Inspect fuel lines.

Inspect air filter. Replace as needed.*

Check external hardware.

Change engine oil.*

Clean air cleaner.*

Check shockmounts. Replace when necessary.

Check and clean spark plug.

Replace oil filter.*

Check and adjust valve clearances.*

Replace in-line fuel filter.*

24

GS 12Ai Maintenance

3.3 Engine Oil

Drain oil while engine is still warm.

3.3.1 Remove oil fill cap (a) and drain plug (b) to drain oil.

Note: In the interests of environmental protection, place a plastic sheetand a container under the machine to collect any liquid which drainsoff. Dispose of this liquid in accordance with environmental protectionlegislation.

3.3.2 Install drain plug and tighten.

3.3.3 Fill the engine crankcase through the oil filler opening to the uppermark on the dipstick (c). See Technical Data for oil quantity and type.

3.3.4 Install oil fill cap and dipstick securely.

3.3.5 To replace the oil filter, remove the installed oil filter after oil has beendrained. Apply a thin coat of oil to the rubber gasket of the replacementoil filter. Screw the filter on until it just contacts the filter adapter, thenturn it an additional 22.24 mm (7/8 in) turn. Refill with oil as describedabove.

a

bc

25

Maintenance GS 12Ai

3.4 Air Cleaner

NEVER use gasoline or other types of low-flash point solvents forcleaning the air cleaner. A fire or explosion could result.

NOTICE: NEVER run the engine without the air cleaner. Severeengine damage will occur.The engine is equipped with a dual-element air cleaner. Under normaloperating conditions, the elements should be cleaned once everyweek. Under severe, dry and dusty conditions, the elements should bemaintained daily. Replace an element when it is saturated with dirt thatcannot be removed.

3.4.1 Remove the air cleaner cover (a). Remove the filter assembly bypulling it straight up. Inspect both elements for holes or tears. Replacedamaged elements.

3.4.2 Wash the foam element (b) in a solution of mild detergent and warmwater. Rinse it thoroughly in clean water. Allow the element to drythoroughly.

3.4.3 Tap the paper element (c) lightly to remove excess dirt or blowcompressed air through the filter from the inside out. Replace thepaper element if it appears heavily soiled.

WARNING

26

GS 12Ai Maintenance

3.5 Spark Plug

Clean or replace the spark plug as needed to ensure proper operation.Refer to your engine operator’s manual. The muffler becomes very hot during operation and remains hot for awhile after stopping the engine. Do not touch the muffler while it is hot.

Note: Refer to section “Technical Data” for the recommended sparkplug type and the electrode gap setting.

3.5.1 Remove the spark plug and inspect it.3.5.2 Replace the spark plug if the insulator is cracked or chipped. 3.5.3 Clean the spark plug electrodes with a wire brush.3.5.4 Set the electrode gap (a).3.5.5 Tighten the spark plug securely.

NOTICE: A loose spark plug can become very hot and may causeengine damage.

WARNING

27

Maintenance GS 12Ai

3.6 Fuel Filter

Check fuel lines and fittings daily for cracks or leaks. Replace asneeded.Change in-line fuel filter (a) once a year. Allow engine to cool, and close fuel valve before replacing fuel filter.

3.7 Engine Speed

Engine speed is pre-set by the manufacturer and should not beadjusted. This ensures that the correct generator voltage is maintainedduring operation.

WARNING

a

28

GS 12Ai Maintenance

3.8 Storage

Before storing generator for a long period of time:

3.8.1 Turn the engine fuel valve to the OFF position.

3.8.2 Disconnect the fuel line from the carburetor. Place open end of fuel lineinto a suitable container and open fuel valve to drain fuel from tank.

Gasoline is extremely flammable. Drain fuel tank in a well ventilatedarea. DO NOT drain tank in an area with flames or sparks.

3.8.3 Loosen the drain screw on the carburetor and drain any remaining fuelfrom carburetor.

3.8.4 Change the engine oil.

3.8.5 Remove the spark plug and pour approximately 30 ml (1 ounce) ofclean engine oil into the cylinder. Crank the engine a few turns todistribute the oil to the inside of the cylinder walls.

3.8.6 Pull the starter rope slowly until resistance is felt and leave handle inthis position. This ensures that the intake and exhaust valves areclosed.

3.8.7 Store generator in a clean, dry area.

3.9 Transport

Let the engine cool before transporting the generator or storing itindoors, to avoid burns or fire hazards.

When transporting the generator:

3.9.1 Turn the engine fuel valve to the OFF position.

3.9.2 Position the generator level to prevent fuel from spilling.

3.9.3 Secure the generator by tying it down with a suitable rope.

When transporting the machine by hand, be sure to employ manpowercommensurate with the weight of the machine. To avoid back injurywhen lifting the machine, bend the knees to pick it up rather thanbending your back only.

WARNING

WARNING

WARNING

29

Maintenance GS 12Ai

3.10 Troubleshooting

3.11 Wire Colors

Problem / Symptom Reason / RemedyIf 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 starting a cold engine.

• All loads are disconnected from generator.

• Spark plug is in good condition.

• Spark plug cap is tight.

• Engine oil level is adequate.

If engine starts but there is no power at receptacles, check that:

• Circuit breaker is closed.

• Connector from generator to control panel is tight.

Wire Colors

B Black R Red Y Yellow Or Orange

G Green T Tan Br Brown Pr Purple

L Blue V Violet Cl Clear Sh Shield

P Pink W White Gr Gray LL Light blue

30

GS 12Ai Maintenance

3.12 Engine Wiring Schematic

Ref. Description Ref. Description

1. Spark Plug 8. Oil Level Switch

2. Ignition Coil 9. Oil Alert Module

3. Engine Stop Diode 10. Rectifier

4. Charging Coil 11. 25 A Fuse

5. Battery 12. Control Box

6. Starter 13. Combination Switch

7. Solenoid

31

Maintenance GS 12Ai

3.13 Generator Wiring Schematic

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 Schuko

10. Volt meter

5. 250 volt/16 Amp receptacle CEE 11. Main stator winding

6. 400 volt/16 Amp receptacle-3 phase

12. Key switch

32

GS 12Ai Technical Data

4. Technical Data

4.1 Generator

Item No. GS 12Ai0620317

Generator

Output 3ø kVA (kW)1ø kVA

11.86

Type Dual voltage, brush-type system

AC Voltages Available volts / phase 400 / 3ø230 / 1ø

Frequency Hz 50

Power Factor 400VAC 3ø230VAC 1ø

0.81.0

400VAC receptacles230VAC receptacles

qty / ampqty / amp

1 / 163 / 16

Main Circuit Breaker amp 16 (4-pole)

Weight (dry) Kg 165

Dimension (L x W x H) mm 960 x 641 x 667

33

Technical Data GS 12Ai

4.2 Engine

Engine Power RatingNet power rating per SAE J1349. Actual power output may vary due toconditions of specific use.

Item No. GS 12Ai0620317

Engine

Engine Make Honda

Engine Model GX 620 K1

Max. rated power @ rated speed

kW 13.5 @ 3600 rpm

Spark Plug NGK: ZGR5A, DENSO: J16CR-U

Electrode Gap mm 0.7 - 0.8

Operating speed rpm 3000 ± 100

Engine Speed - no load rpm 3100 ± 100

Air Cleaner type Dual element

Battery Volt/Amp-hours

12 / 25

Engine Lubrication oil grade SAE 10W30 service class SG or SF

Engine Oil Capacity liters 1.8

Fuel type Regular unleaded gasoline

Fuel Tank Capacity liters 24

Fuel Consumption liters/hr. 3.5

Running Time hrs. 6.9

Valve clearance (cold) mm Inlet: 0.15Outlet: 0.20

34

GS 12Ai Technical Data

4.3 Sound Specifications

The required sound specification, Paragraph 1.7.4.f of 89/392/EECMachinery Directive, is:

• the guaranteed sound power level (LWA) = 96 dB(A).

This sound value were determined according to ISO 3744 for thesound power level (LWA).

35

2008-CE-Gen_GS12Ai_Q.fm

William Lahner Dan DomanskiVice President of Engineering Manager, Product Engineering

WACKER NEUSON CORPORATIONDate / Datum / Fecha / Date

EC DECLARATION OF CONFORMITYCE-KONFORMITÄTSERKLÄRUNG

DECLARACIÓN DE CONFORMIDAD DE LA CE DÉCLARATION DE CONFORMITÉ C.E.

WACKER NEUSON CORPORATION, N92 W15000 ANTHONY AVENUE, MENOMONEE FALLS, WISCONSIN USA

hereby certifies that the construction equipment specified hereunder / bescheinigt, daß das Baugerät / certifica que la máquina de construcción / atteste que le matériel :

1. Category / Art / Categoría / Catégorie Power Generators

KraftstromerzeugerGrupos Electrógenos

Groupe Électrogènes de Puissance

2. Type - Typ - Tipo - Type GS 12Ai

3. Item number of equipment / Artikelnummer / Número de referencia de la máquina / Numéro de référence du matériel :

0620317

4. Electric power / Elektrische Leistung / Potencia eléctrica / Force motrice :

9,47 kWHas been sound tested per Directive 2000/14/EC / In Übereinstimmung mit Richtlinie 2000/14/EG bewertet worden ist / Ha sido ensayado en conformidad con la norma 2000/14/CE / A été mis à l’épreuve conforme aux dispositions de la directive 2000/14/CEE :

and has been produced in accordance with the following standards:und in Übereinstimmung mit folgenden Richtlinien hergestellt worden ist:y ha sido fabricado en conformidad con las siguientes normas:et a été produit conforme aux dispositions des directives européennes ci-après :

2000/14/EC2002/88/EC89/336/EEC98/37/EEC

AUTHORIZED REPRESENTATIVE IN THE EUROPEAN UNIONBEVOLLMÄCHTIGTER VERTRETER FÜR DIE EUROPÄISCHE GEMEINSCHAFTREPRESENTANTE AUTORIZADO EN LA UNIÓN EUROPEAREPRÉSENTANT AGRÉÉ AUPRÈS DE L’UNION EUROPÉENNE

WACKER CONSTRUCTION EQUIPMENT AGPreußenstraße 4180809 München

Conformity Assessment Procedure / Konformitätsbewertungsverfahren / Procedimiento para ensayar conformidad / Procédé pour l’épreuve de conformité

Name and address of notified body / Bei folgender einbezogener Prüfstelle / Oficina matriculadora / Organisme agrée

Measured sound power level / Gemessener Schallleistungspegel / Nivel de potencia acústica determinado / Niveau de puissance acoustique fixé

Guaranteed sound power level / Garantierter Schallleistungspegel / Nivel de potencia acústica garantizado / Niveau de puissance acoustique garanti

Annex VIII / Anhang VIII Anexo VIII / Annexe VIII

Société Nationale de Certification et

Homologation L-5201 Sandweiler# 0499

95 dB(A) 95 dB(A)

28.07.08

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 90Wacker Neuson Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : (262) 255-0500 · Fax: (262) 255-0550 · Tel. : (800) 770-0957Wacker Asia Pacific Operations · Skyline Tower, Suite 2303, 23/F · 39 Wang Kwong Road, Kowloon Bay, Hong Kong · Tel. +852 2406 60 32 · Fax: +852 2406 60 21