Wacker Neuson GS 12Ai Operator's Manual
Operator´s manual
Portable Generator
GS 12Ai
12.2012
5100004227en / 001
Manufacturer
Wacker Neuson Produktion GmbH & Co. KG
Preußenstraße 41
80809 München
www.wackerneuson.com
Tel.: +49-(0)89-354 02-0
Fax: +49-(0)89-354 02-390
Translation of the original operator's manual in German
1Foreword
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1Foreword
This operator's manual contains information and procedures for the safe operation 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 consideration when this machine was designed. Nevertheless, improper use or incorrect 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 2012 Wacker Neuson Prod
uktion GmbH & Co. KG
No part of this publication
may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without the expressed written permission 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 copyr ight
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 standards.
2 Introduction
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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 damage 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.
X Danger 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.
X Danger can be avoided by the following the actions mentioned.
CAUTION
This warning notice indicates possible hazards that can result in minor injury.
X Danger can be avoided by the following the actions mentioned.
NOTICE
This warning notice indicates possible hazards that can result in material damage.
X Danger can be avoided by the following the actions mentioned.
2 Introduction
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Instructions
X This 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 information is needed to order spare parts and when requesting additional technical
information.
X Enter 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.
Translation of the original Declaration of Conformity
EC Declaration of Conformity
Manufacturer
Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München
Product
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/EG, 2006/95/EG, 2000/14/EG, 2004/108/EG, 2011/65/EU
Authorized person for technical documents
Axel Häret,
Wacker Neuson Produktion GmbH & Co. KG, Preußenstraße 41, 80809 München
Product
GS 12Ai
Product category Generator
Product function Electricity generation
Item number 0620317
Net installed power 9,47
Measured sound power
level
95 dB(A)
Guaranteed sound power
level
95 dB(A)
Dr. Michael Fischer
Director of Technology and Innovation
München, 10.12.2012
Table of ContentsGS 12Ai
Foreword 3
EC DECLARATION OF CONFORMITY 7
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 ............... 15
1.5 Service Safety .................................................................................... 16
2 Labels 18
3 Lifting and Transporting 20
3.1 Using the Lifting Beam .......................................................................20
3.2 Transporting the Machine ................................................................... 21
4 Operation 22
4.1 Preparing the Machine for First Use ................................................... 22
4.2 Power Requirements .......................................................................... 22
4.3 Installation .......................................................................................... 23
4.4 Generator Derating ............................................................................. 24
4.5 Use of Extension Cords ...................................................................... 25
4.6 Isolation Monitor ................................................................................. 28
4.7 Control Panel ...................................................................................... 29
4.8 Before Starting ...................................................................................30
4.9 Starting ...............................................................................................30
4.10 Stopping ............................................................................................. 31
4.11 Emergency Shutdown Procedure ...................................................... 31
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Table of Contents GS 12Ai
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 Maintaining the Fuel Filter ...................................................................36
5.6 Engine Speed ......................................................................................36
5.7 Replacing the Fuse .............................................................................36
5.8 Troubleshooting ...................................................................................37
5.9 Wire Colors ..........................................................................................37
5.10 Engine Wiring ......................................................................................38
5.11 Generator and Receptacle Wiring .......................................................39
5.12 Long-Term Storage .............................................................................40
6 Technical Data 41
6.1 Generator ............................................................................................41
6.2 Engine .................................................................................................42
6.3 Sound Measurements .........................................................................43
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GS 12Ai Safety Information
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.
This is the safety alert symbol. It is used to alert you to potential personal hazards.
f Obey all safety messages that follow this symbol.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
f
To 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.
To avoid possible death or serious injury from this type of hazard, obey all safety mes-
f
sages that follow this signal word.
CAUTION!
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
f
To avoid possible minor or moderate injury from this type of hazard, obey all safety messages that follow this signal word.
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.
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Safety Information GS 12Ai
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 connect s 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
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GS 12Ai Safety Information
• 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
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
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.
This may result in electrocution of utility workers, fire, or explosion.
Connections to a building’s electrical system must be made by a
qualified electrician and comply with all applicable laws and electrical
codes.
If connected to a building’s electrical system the generator must meet
the power, voltage, and frequency requirements of the equipment in
the building. Differences in power, voltage, and frequency
requirements may exist and improper connection may lead to
equipment damage, fire, and personal injury or death.
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Safety Information GS 12Ai
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
WARNING
1.3.1 NEVER operate the generator when open containers of fuel, paint, or
1.3.2 NEVER operate the generator, or tools attached to the generator, with
1.3.3 NEVER use worn electrical cords. Severe electrical shock and
1.3.4 NEVER run the electrical cords under the generator, or over vibrating
1.3.5 NEVER enclose or cover the generator when it is in use or when it is
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.
other flammable liquids are near.
wet hands.
equipment damage may result.
or hot parts.
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.
1.3.9 NEVER connect generators with isolation monitors in parallel. This
would affect the operation of the isolation monitor.
1.3.10 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.
1.3.11 ALWAYS position and operate the generator on a firm,
noncombustible, level surface.
1.3.12 ALWAYS transport the generator in an upright position.
1.3.13 ALWAYS keep the machine at least one meter (three feet) away from
structures, buildings, and other equipment during use.
1.3.14 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.
1.3.15 ALWAYS remove all tools, cords, and other loose items from the
generator before starting it.
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GS 12Ai Safety Information
1.4 Operator Safety while Using Internal Combustion Engines
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.
f Read and follow the warning instructions in the engine owner’s manual and the
safety guidelines below.
DANGER
Asphyxiation hazard.
f NEVER use this generator inside a home or garage, EVEN IF doors and win-
dows are open. Only use OUTSIDE and far away from windows, doors, and
vents. Using a generator indoors CAN KILL YOU IN MINUTES. Generator
exhaust contains carbon monoxide. This is a poison you cannot see or smell.
f NEVER use a generator inside an enclosed area such as a tunnel or a trench.
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.
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