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.: [phone]
Fax: [phone]

Translation of the original operator's manual in German

1Foreword

3

100_0000_0002.fm

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

5

100_0000_0003.fm

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

100_0000_0003.fm6

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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Safety Information GS 12Ai

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

WARNING

Personal Protective Equipment (PPE)

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.

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.

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GS 12Ai Safety Information

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.

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.

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2 Safety and information labels

100_0402_ls_0003.fm 18

2 Safety 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.

2 Safety and information labels

19

100_0402_ls_0003.fm

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.

5 Close the fuel flow valve.

Open the fuel flow valve.

Item Label Description

GS 12Ai Lifting and Transporting

3 Lifting and Transporting

3.1 Using the Lifting Beam

Description

Your machine may be equipped with a lifting beam as shown in the
illustration below. The lifting beam is available as an accessory kit
(part number 0177442) from your Wacker Neuson dealer.

wc_gr006712

Guidelines for lifting safety

If your machine is equipped with a lifting beam, observe the following
guidelines:

• The equipment used to lift the machine must have suitable

dimensions and weight-bearing capacity.

• Stop the engine before lifting the machine.

• Do not sit or stand on the machine while it is being lifted.

• Use smooth, steady movements to lift the machine. The descent /

lifting speed must not exceed 200 mm/s (approx. 7 in./s).

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Lifting and Transporting GS 12Ai

3.2 Transporting the Machine

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

WARNING

When transporting the generator:

3.2.1 Turn the engine fuel valve to the OFF position.

3.2.2 Position the generator level to prevent fuel from spilling.

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

When transporting the machine by hand, be sure to employ manpower
commensurate with the weight of the machine. To avoid back injury

WARNING

when lifting the machine, bend the knees to pick it up rather than
bending your back only.

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GS 12Ai Operation

4 Operation

4.1 Preparing the Machine for First Use

Preparing for first use

To prepare your machine for first use:

4.1.1 Make sure all loose pa ckaging materials have been removed from the
machine.

4.1.2 Check the machine and its components for damage. If there is visible
damage, do not operate the machine! Contact your Wacker Neuson
dealer immediately for assistance.

4.1.3 Take inventory of all items included with the machine and verify that
all loose components and fasteners are accounted for.

4.1.4 Attach component parts not already attached.

4.1.5 Add fluids as needed and applicable, including fuel, engine oil, and
battery acid.

4.1.6 Move the machine to its operating location.

4.2 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.

NOTICE: Do not exceed the power output of the generator. Damage
to tools or generator will occur. See Technical Data.

Check the nameplate or label provided on tools and appliances to
make sure their power requirements are met by the power output of the
generator. 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 the
equipment is larger than the power required to keep it running. The
generator must be capable of supplying this "surge" current. Other
types of appliances require more power than is actually stated on their
nameplate.

The information in “Approximate Starting Power Requirements” is
offered only as a general guideline to help you determine power
requirements for different types of equipment. Check with your nearest
Wacker Neuson dealer, or contact the manufacturer or dealer of the
tool 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 few

seconds after it is switched on, turn it off immediately to avoid damage.

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Operation GS 12Ai

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 watt­age 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 start­ing.

• 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 be
calculated by multiplying its voltage and amperage requirements:

Single Phase: VOLTS x AMPS = WATTS

4.3 Installation

DANGER

DANGERDANGER

Three Phase: VOLTS x AMPS x 1.732 x 0.8 = WATTS

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.

The surrounding area must be free from water and moisture. All
components must be protected from excessive moisture.

Using a generator indoors CAN KILL YOU IN MINUTES. Generator
exhaust contains carbon monoxide. This is a poison you cannot see or
smell. NEVER use this generator inside a home or garage, EVEN IF
doors and windows are open. Only use this generator OUTSIDE and
far away from windows, doors, and vents.

NEVER install a generator in an enclosed area such as a tunnel or a
trench. Using a generator in a tunnel or a trench CAN KILL YOU IN
MINUTES. Generator exhaust contains carbon monoxide. This is a
poison you cannot see or smell. NEVER use this generator inside a
tunnel or a trench.

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GS 12Ai Operation

4.4 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.
Temperature affects both engine and generator performance. As
temperature increases, an engine will run less efficiently and more
resistance will be found in electrical components. Therefore, as the
temperature increases, the output of the generator decreases.
Altitude also affects the cooling capacity of air—the higher the altitude
the less dense 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 (3300
ft.), the output of the generator will be reduced by 3%. For every
increase 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 tables
shown for altitude and temperature deration factors. It may be
necessary to consider both altitude and ambient temperature deration
factors 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

Altitude

m (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

wc_tx001589gb.fm 24

4000 (13100) 18 % 0.82

Operation GS 12Ai

4.5 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. A cord with a larger cross section will reduce the voltage
loss.

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 cause

serious injury or death. DO NOT use worn, bare, or frayed cords.
Replace damaged cords immediately.

WARNING

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 or

calculate minimum cord size using the Minimum Extension Cord Size
Graph. The X axis of the graph represents A x m (Ampere x meter)
values. The Y axis represents wire size in mm2. Multiply the operating
current for the load in amps (A) by the desired extension cord length in
meters (m). Find the result along the X axis. Move up the graph until
you reach the appropriate sloped line for your application. Move to the
Y axis; this is the recommended minimum cord size.

Example:
For a 3-phase, 400V application, if the operating current for the load is

15 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.

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GS 12Ai Operation

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

20.75 1.5

41.5 2.5

61.5 4

82.5 4
10 2.5 6
15 4 10
20 6 10
25 6 16
30 10 16

Minimum Extension Cord Size 400V

400 V

Amp Rating

Diameter of cord, mm2

2

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

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Operation GS 12Ai

mm

25
16
10

2

6
4

2.5

1.5

0

1000

2000

3000 4000 5000

A x m

0

3

2

~

1

0

4

~

3

z

H

0

5

V

z

H

0

5

V

0

6000

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GS 12Ai Operation

4.6 Isolation Monitor

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. The Isolation Monitor protects the operator from
a ground fault by sensing a resistance change, as in a short to ground,
on the output of the generator. When the Isolation Monitor senses a
resistance change, it lights the TEST button and it causes the relay to
open, which mechanically trips the main circuit breaker. The Isolation
Monitor cannot be reset with the generator running. Before the
main circuit breaker can be closed, the generator must first be shut
down, the fault cleared, and the generator restarted.

To test the Isolation Monitor:
Start the generator. Place the main circuit breaker in the closed

position (e1). Push the TEST button (b). The TEST button will light up,
and the main circuit breaker will move to the open position (e2). Power
is now off at the receptacles. If the breaker does not open, the Isolation
Monitor is not working. Do not use the generator until the problem can
be corrected. To restore power to the receptacles, shut down the
generator, restart it, and place the circuit breaker in the closed position
(e1).

The main circuit breaker is current-operated and shuts off the power to
the receptacles when an overcurrent occurs that is greater than what
the breaker is rated for.

If the circuit breaker lever opens during operation, stop the generator
and check the generator and any equipment it was powering for
defects. Repair all defects before operating the generator.

wc_tx001589gb.fm 28

Operation GS 12Ai

4.7 Control Panel

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. Check the
appliances and tools attached to the generator for defects and make
sure their power requirements do not exceed the power rating of the
generator or the current limit of the receptacles.

When the circuit breaker opens, the breaker lever will snap down. To
reset circuit breaker, lift lever up.

The generator has following type of receptacles:

• One 250 volt, IP54 (c)

• One 250 volt, large flange, IP54 (e)

• one 230 volt, IP44 CEE (d)

• one 400 volt, 3-phase 5 pin receptacle IP44 CEE (b)

c d e b

a

wc_gr007686

29 wc_tx001589gb.fm

GS 12Ai Operation

4.8 Before Starting

4.8.1 Read and understand safety and operating instructions at beginning of
this manual.

4.8.2 Read and understand the meanings of all warning and operating
labels.

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

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

4.8.5 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

4.9 Starting

4.9.1 Disconnect all loads from the generator and place main circuit breaker

4.9.2 Open fuel valve.

4.9.3 If engine is cold, move choke lever to closed position (a1). If engine is

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

4.9.5 Open choke as engine warms (a2).

4.9.6 Place main circuit breaker in closed position (e1). Allow th e engine to

lever in open position (e2).

hot, set choke to open position (a2).

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 not
running. Leaving the key in the RUN position with the engine off will
drain the battery.

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

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

wc_tx001589gb.fm 30

Operation GS 12Ai

4.10 Stopping

4.10.1 Turn off and disconnect all tools and appliances attached to the
generator.

4.10.2 Place main circuit breaker in open position (e2).

4.10.3 Turn engine switch to “OFF” (b1).

4.10.4 Turn fuel valve off.

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

4.11 Emergency Shutdown Procedure

Procedure

If a breakdown or accident occurs while the machine is operating,
follow the procedure below:

4.11.1 Stop the engine.

4.11.2 Turn off the fuel supply.

4.11.3 Disconnect tools from the machine.

4.11.4 Allow the machine to cool.

4.11.5 Contact the rental yard or machine owner for further instructions.

31 wc_tx001589gb.fm

GS 12Ai Maintenance

5 Maintenance

5.1 Periodic Maintenance Schedule

The table below lists basic machine and engine maintenance. Tasks
designated with check marks may be performed by the operator.
Tasks designated with square bullet points require special training
and equipment.
Refer to the engine owner’s manual for additional information.

Check engine oil level.

Inspect fuel lines.

Inspect air filter.

Check external hardware.

Check fuel level.

Change engine oil.
Clean air cleaner.*
Check and adjust spark

plug.
Replace oil filter.

Replace spark plug

Daily

before

starting

3

3

3

3

3

First

month or

20 hrs.



Every 6
months
or 100
hrs.





Every 200 hours

Every
year or
300 hrs.



Every 2
years or
500 hrs.

Check and adjust idle
speed.

Check and adjust valve
clearances.*

Replace fuel filter.*
Replace air cleaner.
Clean combustion cham-

ber.

* Service more frequently in dusty conditions

wc_tx001590gb.fm 32









Every 1000 hours

Maintenance GS 12Ai

5.2 Engine Oil

Drain oil while engine is still warm.

5.2.1 Remove oil fill cap (a), drain plug (b), and washer (c) to drain oil.

a

c

b

Note: In the interests of environmental protection, place a plastic sheet

and a container under the machine to collect any liquid which drains
off. Dispose of this liquid in accordance with environmental protection
legislation.

5.2.2 Reinstall drain plug and tighten.

5.2.3 Fill engine crankcase with recommended oil to the upper limit mark on
the dipstick (d).

5.2.4 Reinstall oil fill cap and dipstick securely.

d

f

e

g

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5.2.5 To replace the oil filter (e), remove the installed oil filter after oil has
been drained. Apply a thin coat of oil to the rubber gasket (f) of the
replacement oil filter. Screw the filter on until it just contacts the filter
adapter (g), then turn it an additional 22.24 mm (7/8 in.) turn. Refill with
oil as described above.

33 wc_tx001590gb.fm

GS 12Ai Maintenance

5.3 Servicing the Air Cleaner

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

WARNING

NOTICE: NEVER run the engine without the air cleaner. Severe
engine damage will occur.

The engine is equipped with a dual-element air cleaner. Under normal
operating conditions, the elements should be cleaned every six
months or 100 hours. Under severe, dry and dusty conditions, the
elements should be maintained daily. Replace an element when it is
saturated with dirt that cannot be removed.

5.3.1 Remove the air cleaner cover (a).

a

c

b
d

wc_gr007591

5.3.2 Loosen the wing nut (b) and remove it.

5.3.3 Remove the filter assembly by pulling it straight up. Inspect both
elements for holes or tears. Replace damaged elements.

5.3.4 Wash the foam element (c) in a solution of mild detergent and warm
water. Rinse it thoroughly in clean water. Allow the element to dry
thoroughly.

5.3.5 Tap the paper element (d) lightly to remove excess dirt or blow
compressed air through the filter from the inside out. Replace the
paper element if it appears heavily soiled.

5.3.6 Reinstall the filter elements.

5.3.7 Reinstall the air cleaner cover.

wc_tx001590gb.fm 34

Maintenance GS 12Ai

5.4 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 a
while after stopping the engine. Do not touch the muffler while it is hot.

WARNING

Note: Refer to section “Technical Data” for the recommended spark

plug type and the electrode gap setting.

5.4.1 Remove the spark plug and inspect it.

5.4.2 Replace the spark plug if the insulator is cracked or chipped.

5.4.3 Clean the spark plug electrodes with a wire brush.

5.4.4 Set the electrode gap (a).

5.4.5 Tighten the spark plug securely.

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

35 wc_tx001590gb.fm

GS 12Ai Maintenance

5.5 Maintaining the Fuel Filter

5.5.1 Change the in-line fuel filter (a) once a year or every 300 hours of
operation. Check the fuel lines and fittings daily for cracks or leaks.
Replace as needed.

Gasoline is extremely flammable! Turn the engine off and allow the
engine to cool before replacing the fuel filter.

WARNING

5.6 Engine Speed

Engine speed is pre-set by the manufacturer and should not be
adjusted. This ensures that the correct generator voltage is maintained
during operation.

5.7 Replacing the Fuse

Refer to engine owner’s / operator’s manual.

wc_tx001590gb.fm 36

Maintenance GS 12Ai

5.8 Troubleshooting

Problem / Symptom Reason / Remedy

If engine doesn't start, check

that:

If engine starts but there is no
power at receptacles, 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.

• Circuit breaker is closed.

• Connector from generator to control panel is tight.

5.9 Wire Colors

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

37 wc_tx001590gb.fm

GS 12Ai Maintenance

5.10 Engine Wiring

Gr

Bl

3

Gr

Bl

Y

Bl

Bl Bl

Bl/Y

Gr

Gr

Bl

Bl

Bl/Y

W

W W

2

1

W

Bl/W

Y

4

Y

Bl

6

8

W

W

9

W

Bl/WBlBl/Y

G

G

7

5

2

1

Ref. Description Ref. Description

1 Spark plug 6 Fuel cutoff solenoid
2 Ignition coil 7 Oil level switch
3 Charging coil 8 Regulator rectifier
4 Battery 9 Main fuse
5 Starter motor 10 Engine switch

10

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wc_tx001590gb.fm 38

Maintenance GS 12Ai

5.11 Generator and Receptacle Wiring

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
5 250 volt/16 Amp receptacle CEE 11 Main stator winding
6 400 volt/16 Amp receptacle-3

phase

10 Volt meter

12 Key switch

39 wc_tx001590gb.fm

GS 12Ai Maintenance

5.12 Long-Term Storage

Before storing generator for a long period of time:

5.12.1 Turn the engine fuel valve to the OFF position.

5.12.2 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.

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

WARNING

5.12.3 Loosen the drain screw on the carburetor and drain any remaining fuel
from carburetor.

5.12.4 Change the engine oil.

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

5.12.6 Pull the starter rope slowly until resistance is felt and leave handle in
this position. This ensures that the intake and exhaust valves are
closed.

5.12.7 Store generator in a clean, dry area.

wc_tx001590gb.fm 40

GS 12Ai Technical Data

6 Technical Data

6.1 Generator

Item No.

GS 12Ai

Generator

Output

3ø kVA (kW)

1ø kVA

11.8
6

Type Compound with brush-type system
AC Voltages Available

volts / phase

400 / 3ø

230 / 1ø
Frequency
Power Factor 400VAC 3ø

230VAC 1ø

400VAC receptacles
230VAC receptacles

Main Circuit Breaker
Weight (dry)

Hz

qty / amp
qty / amp

amp

Kg

50

0.8

1.0

1 / 16
3 / 16

16 (4-pole)

168

Dimension (L x W x H)

mm

963 x 641 x 667

wc_td000416gb.fm 41

Technical Data GS 12Ai

6.2 Engine

Engine Power Rating

Net power rating per SAE J1349. Actual power output may vary due to
conditions of specific use.

Item No.

GS 12Ai

Engine

Engine Make Honda
Engine Model GX 630
Max. rated power @

kW

15.5 @ 3600 rpm

rated speed
Spark Plug NGK: ZFRF5
Electrode Gap
Operating speed
Engine Speed - no load
Air Cleaner
Battery

Engine Lubrication

mm
rpm
rpm

type

Volt/Amp-

hours

oil grade

0.7 - 0.8
3000 ± 100
3100 ± 100

Dual element

12 / 25

SAE 10W30 service class SG or SF
Engine Oil Capacity
Fuel
Fuel Tank Capacity
Fuel Consumption
Running Time, 3/4 Load
Valve clearance (cold)

liters

type

liters

liters/hr.

hrs.
mm

1.9

Regular unleaded gasoline

24

3.9

6.2

Inlet: 0.15

Outlet: 0.20

42 wc_td000416gb.fm

GS 12Ai Technical Data

6.3 Sound Measurements

The required sound specification, Paragraph 1.7.4.2.u of 2006/42/EEC
Machinery Directive, is:

• the guaranteed sound power level (L

) = 95 dB(A).

WA

This sound value was determined according to ISO 3744 for the sound
power level (L

WA

).

wc_td000416gb.fm 43