Thank you for buying a GESAN generator set.

This manual has been written to assist you in maintaining and operating your generator set correctly. Please read it carefully before putting the machine into operation so as to become familiar with the precautions to be taken during use and be able to perform maintenance in ideal conditions. Please keep this manual on hand for consultation at all times and ensure it is included with the machine should it be re-sold. GRUPOS ELECTROGENOS GESAN, S.A. is constantly striving to improve its products, and regularly introduces changes to the equipment it supplies. For this reason the characteristics and information contained in this manual may be modified without prior notice and without incurring any obligation. If any problems or queries arise, please contact your distributor.

CONTENTS
SAFETY INSTRUCTIONS..................................................................................3 GENERAL DESCRIPTION.................................................................................6 LABELS..............................................................................................................7 BEFORE USE.....................................................................................................9 1.1 Oil recommended ...........................................................................9 1.2 Oil level check ................................................................................ 9 1.3 Fuel recommended .......................................................................10 1.4 Fuel level check ..........................................................................10 OPERATION.....................................................................................................12 1. Starting the engine.........................................................................12 1.1 Starting using the electric starter......................................12 1.2 Starting using the starter rope..........................................14 2. Running the engine.........................................................................16 3. Stopping the engine........................................................................16 4. Operating the generator set............................................................17 5. Commissioning...............................................................................18 MAINTENANCE................................................................................................18 1. Maintenance schedule...................................................................19 2. Oil change......................................................................................19 2.1 Oil filter change................................................................20 3. Air filter ..........................................................................................20 3.1 Air filter change................................................................21 4. Spark-plug maintenance...... ......................................................... 21 HANDLING, TRANSPORT AND STORAGE.................................................. 22 1. Handling ........................................................................................22 2. Transport ...................................................................................... 23 3. Long term storage.............................. .......................................... 23 WIRING DIAGRAMS........................................................................................ 24 TROUBLESHOOTING .................................................................................... 27 CHARACTERISTICS....................................................................................... 28

SAFETY INSTRUCTIONS

Please read carefully the following instructions for your own safety and the safety of others :

1. Make sure that the control panel is well-lit if you run your generator set in poor operating conditions. 2. Make sure that you know how to stop the generator set in case of emergency and familiarise yourself with its controls and power outlets.

Do not permit operation by someone unfamiliar with the generator set. Do not let children operate the generator set without the help of an adult. Children and pets must be kept at a safe distance from the engine, in order to avoid burns or injury.

3. Carry out all necessary checks before starting the generator set in order to avoid accidents or damage to the equipment. 4. Earth the generator set as well as the load properly.

5. Do not operate the generator set when it is raining or where there is snow. YOU MAY BE ELECTROCUTED.

Do not get the generator set wet, or operate it with wet hands..

6. Do not connect the generator set to the mains. Connection should be carried out by a qualified electrician in accordance with all applicable standards and regulations. A poorly made connection may cause current returns which could lead to the electrocution of anybody working on the mains.

7.- The engine exhaust emits sufficient heat to set some substances on fire.

Keep the generator set away from buildings and other equipment (at least one metre).

Keep all inflammable substances away from the generator set. Wait until the engine has cooled down before carrying out maintenance or storing it.
8. The fuel used is highly inflammable and volatile :

Ensure that the engine is not running before filling the fuel tank and that the premises are sufficiently ventilated. Do not over-fill the fuel tank. After filling, ensure the fuel cap is properly closed. Do not get near flames or sparks while filling the fuel tank. DO NOT SMOKE near the generator set. Keep the generator set on a firm, level surface, otherwise fuel may spill and catch light.
9. Exhaust fumes from the engine are poisonous:

Do not operate the generator set in a closed environment.

If operating the set in an enclosed space, provide adequate ventilation and direct the exhaust fumes out of the area. 10. If the generator set is used in a place where damp and dust are unavoidable, it must be dried and cleaned regularly. 11. At the slightest abnormality, stop and disconnect the set. Locate and correct the fault before starting up again.

12. Regularly inspect all electrical cables. If damaged cables or hazardous situations are found, stop the unit immediately and replace or correct the faulty cables before starting up again.
13. Handle batteries with care. Batteries give off explosive gases; keep sparks, flames and cigarettes well away. Provide adequate ventilation when charging or using batteries in enclosed spaces. Batteries contain sulphuric acid (electrolyte). Contact with the skin or eyes can cause severe burning. Wear protective clothing and a protective mask. If electrolyte comes into contact with skin, wash with water. If electrolyte comes into contact with eyes, wash eyes with water for at least 15 minutes and seek medical assistance immediately. 4

Electrolyte is poisonous. If you swallow it, drink large amounts of water or milk, and follow with milk of magnesia or vegetable oil and seek medical assistance. Use only distilled water in batteries. Tap water will shorten battery life. If the battery is filled above the maximum level the electrolyte will overflow causing corrosion of the engine or adjacent parts. Clean away electrolyte which has been spilled. 14. Used oil can cause skin cancer in cases of prolonged and frequent contact. Although this is unlikely, hand washing after contact with used motor oil is recommended.

KEEP OUT OF THE REACH OF CHIDREN.

For further information or enquiries please contact : GRUPOS ELECTROGENOS GESAN S.A. Polgono Malpica-Alfindn, c/ Encina, n 8 50171 La Puebla de Alfindn (Zaragoza) SPAIN Phone: (+34) 976 107 332 Fax: (+34) 976 107 366 E-mail: export@gesan.com

GENERAL DESCRIPTION G 12000 H, G 12 TF H

1- Frame 2- Engine 3- Alternator 4- Engine dampener 5- Alternator dampener 6- Fuel filler cap 7- Fuel tank 8- Battery 9- Fuel tap 10- Air filter 11- Exhaust pipe 12- Engine oil drainage plug

13- Control panel 14- Ignition key box 15- On light 16- 230 V socket 17- Circuit breaker 18- Voltmeter 19- Hours run meter 20- 230 V socket (G 12000 H) 400 V socket (G 12 Tf H)

LABELS
On your generator set you will find the following labels:

LABEL No. 1 (UNDEFINED DANGER)

LABEL No. 2

LABEL No. 3 This label may indicate 230 or 400 V.

LABEL No. 4 (EARTH)

LABEL No.5 (ELECTRICAL HAZARD) 7

LABEL No. 6

For your own safety and the safety of others, please replace these labels immediately if lost or damaged.
LOCATION OF LABELS Label no. 1 is located on the fuel tank, or on the air filter (as near as possible to the exhaust outlet). This label is also found on the sides of the alternator. (See picture). Labels 2 and 3 are located on top of the alternator. (Three phase generator sets do not have label no. 2). Label no. 4 is located on the frame, next to the earth screw. Label no. 5 is located on the alternator cap and on the control panel (if supplied). Label no. 6 is located on top of the fuel tank.

BEFORE USE
To carry out the following checks place the generator set on a firm, level surface. 1.1 OIL RECOMMENDED The use of SAE 10W30 motor oil is recommended, for all temperatures in general. It is however wise to select from the table the viscosity applicable to the average temperature of the area where the set is to be used.

* The oil used is of vital importance as it affects the performance and life expectancy of the engine. *Running the engine with insufficient oil may result in major damage. *Do not use non-detergent or vegetable oils .

1.2 OIL LEVEL CHECK a) Remove the oil filler cap (1) and clean the dipstick (2) with a clean cloth. b) Insert the dipstick into the oil filler vent without screwing in. c) If the level is under the minimum, add recommended oil up to the upper limit.

1.3 FUEL RECOMMENDED Use car petrol, preferably UNLEADED or with a low lead content in order to reduce deposits in the combustion chamber.

Fuel tank capacity: 13 litres

WARNING !!!
* Do not use oil/petrol mixture or dirty/old fuel. * Do not let dirt or water get into the tank. * Do not use petrol containing alcohol. NOTE: The warranty does not cover damage caused by the use of unsuitable fuel.

1.4 FUEL LEVEL CHECK a) Remove fuel tank cap. b) Add fuel and replace cap.

WARNING !!!
Fill fuel tank in well ventilated premises and with the engine turned off. Do not smoke or allow sparks or flames in the area where the engine is refuelled or where fuel is stored. Do not overfill the fuel tank and make sure that filling the tank, the fuel cap has been screwed on properly . Take care not to spill fuel when filling. Fuel fumes or spilled fuel may catch light. If fuel is spilled, ensure that the area is dry before starting the engine. Avoid repeated or prolonged contact with the skin and avoid inhaling fumes. KEEP FUEL OUT OF THE REACH OF CHILDREN.

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Fuel consumption may increase with altitude as the air/ fuel mixture becomes richer. If you use your generator set at altitudes higher than 1800 m above sea level, please consult.

At high altitude, the air/fuel mix in the carburettor becomes too rich. Engine efficiency will be reduced and fuel consumption will increase. If the engine is always used at high altitude (above 1830m), efficiency may be improved by installing in the carburettor a smaller diameter main fuel distributor, and by readjusting the guide screw. Have your local dealer perform these modifications on the carburettor. A petrol engines loses 3.5% power for every 300 metres above sea level. Altitude will affect engine power even more if the carburettor is not modified.

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OPERATION
1. STARTING THE ENGINE

WARNING !!!

Check that nothing is connected to the generator set output sockets. The engine must be connected to the battery to activate the fuel cut-out solenoid, allowing the engine to run. If the battery is disconnected, fuel flow to the carburettor main distributor will be interrupted. If the fuel tank has a valve, check that it is in the OPEN or ON position before attempting to start the engine. 1.1 STARTING THE ENGINE USING THE ELECTRIC STARTER a) Pull the choke knob out to the CLOSE position to start a cold engine. The choke may not be necessary if the engine is hot or air temperature is high.

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b) Turn the engine switch to the START position and hold it there for about 5 seconds or until the engine starts. NOTE: Do not use the electric starter more than 5 seconds each time. If the engine does not start, release the key and wait 10 seconds before trying again.

c) When the engine has started, return the switch to the ON position.

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1.2 STARTING THE ENGINE USING THE ROPE STARTER

a) Pull the choke knob out to the CLOSE position to start a cold engine. The choke may not be necessary if the engine is hot or air temperature is high.

b) Turn the engine switch to the ON position .

c) Pull out the starter grip until it bites back. Then pull out sharply. 14

WARNING !!!

* Do not let the starter grip snap back against the engine. Let it pull back slowly to avoid damaging the starter.

Oil alert system (if supplied) The oil alert system is designed to prevent engine damage caused by a lack of oil in the oil sump. Before the oil level in the sump falls below the safety limit, the oil alert system automatically stops the engine (the engine switch remains in the ON position),

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2. RUNNING THE ENGINE a) As the engine warms up, press the choke knob in to the OPEN position.

Do not disconnect the battery while the engine is running. This will disactivate the fuel cut-out solenoid and cut off fuel flow to the carburettor main distributor, thus stopping the engine.

3. STOPPING THE ENGINE To stop the engine in an emergency, turn the engine switch to the OFF position. Otherwise, follow the procedure below:

a) If the fuel tank has a valve, turn the fuel valve to the CLOSED or OFF position. b) Turn the engine switch to the OFF position.

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4. OPERATING THE GENERATOR SET

Once the engine is running, your GESAN generator set is ready to provide you with the service which was the reason for your purchase.
However, please let us repeat the instructions to be followed for your own safety and the correct running of your generator set:

WARNING !!!

* Do not connect the generator set to the mains. * Do not start the generator without checking that nothing is connected to the output sockets. * Do not change the cable connections. * Do not change the engine speed: The frequency and the voltage directly depend on the rotation speed of the engine. This adjustment IS CARRIED OUT AT THE FACTORY. MANIPULATING THE ACCELERATOR OF THE ENGINE ENTAILS THE LOSS OF THE GUARANTEE. * Do not connect equipment using a voltage different from that supplied by the generator set. * This generator set is not suitable for use with electrical equipment such as television sets, hi-fi equipment, computers, etc. * Before connecting an electric welder, please consult our technical department. Current peaks MAY BURN THE ALTERNATOR. * Do not charge batteries on the D.C. outlets. When included on the alternator they are intended as an auxiliary output. Their current ratings can be found in the characteristics included at the end of this manual. * Avoid overloads. For problem-free operation remember that: - The sum of the power ratings of the equipment connected to the generator set has to be compatible with the characteristics included at the end of this manual. - Some apparatus (electric motors, air compressors, etc.) absorb power higher than their nominal power rating when starting. Please consult your distributor in each case.

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- Do not exceed the maximum current values indicated for each output socket.

5. COMMISSIONING 1. Connect equipment to the output sockets, making sure not to surpass the maximum current specified for each output. 2. Ensure that the cooling air inlet and outlet vents are not obstructed.

MAINTENANCE
To obtain the best performance and the longest life from your GESAN generator set, you must ensure that maintenance is carried out regularly. It is therefore vital that you follow the following maintenance schedule.

WARNING !!!

*The engine and the exhaust pipe reach very high temperatures and can cause serious burns or set inflammable substances on fire if close by. Let the engine cool down for at least 15 minutes before carrying out maintenance. *Using NON ORIGINAL or equivalent parts may cause damage to your generator set.

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1. MAINTENANCE SCHEDULE The following schedule contains a summary of the maintenance instructions which are indicated in months or hours of operation so as to help you to choose the best periods :
At each use First month Every 3 or 20 hours months or every 50 hours Every 6 Every year or every 300 months or hours every 100 hours

Item
Engine oil

Operation
Check the level Change

Air filter element

Check Clean (*)

Oil filter Spark plug Spark arrestor Valve play Fuel filter Fuel line

Change Clean and adjust Clean Check and adjust Change Change Every 2 years(***)

Every 200 hours

(**) (**) (**)

(*) Clean more frequently in a dusty environment (**) Maintenance to be carried out by a specialist unless tools are available. 2. OIL CHANGE

WARNING !!!

* Used oil can cause skin cancer in cases of prolonged and frequent contact. Although this is unlikely, wash your hands after handling used motor oil. To obtain rapid and complete oil draining, it is advisable to drain the engine sump as soon as possible after the recommended cooling period (15 min. approximately).

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NOTE: Used oil is a major pollutant. We recommend you take it in a closed container to a service station or a waste disposal station. Do not discard it with household rubbish and do not pour it on the ground or into the sewerage system.

2.1 OIL FILTER CHANGE a) Drain engine oil. b) Remove oil filter using filter wrench and let remaining oil drain away. Discard oil filter. c) Clean filter base. d) Coat new joint with clean motor oil and fit it to the base of the filter. e) Fit new oil filter and tighten by hand until joint is firmly in place. f) Turn filter to the specified angle or torque with a torque wrench: Angle: 7/4 of a turn Torque: 22 N-m (2.2 Kg-m) g) Add specified amount of motor oil. Start the engine and check to see if there are any leaks. h) Stop the engine and check the oil level again. If necessary, add oil to reach the correct level. NOTE: Ask you authorised Honda dealer for advice on the filter wrench (special tool).

3. AIR FILTER

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A blocked air filter can affect the running of the engine and cause an increase in fuel consumption. Regular maintenance of this filter is therefore necessary.

WARNING !!!
* Never use petrol or other inflammable substances for cleaning air filter elements. These substances can catch light and damage these elements.

WARNING !!!
* Never use the generator set without an air filter, it could damage the engine. 3.1 AIR FILTER CHANGE a) Extract filletted bolt and air filter cover. b) Extract the two 5 mm screws from the air filter cover and extract the paper element from the cover. Extract the foam element from the air filter body. c) Foam element: Clean with warm water and a small amount of detergent and drain thoroughly. Coat the element with clean motor oil and drain off excess oil. The engine will smoke when it starts up if too much oil is left on the foam.

d) Paper element: Tap the element several times on a hard surface to remove dust, or blow compressed air (not more than 2.1 kg/cm2) through the filter from the air filter cover side. Change paper element if very dirty. Replace paper element and reassemble filter.
4. SPARK-PLUG MAINTENANCE

WARNING !!!
* If the engine is still hot, do not touch the exhaust pipe or the spark-plug. You could burn yourself badly. a) Remove the cap and unscrew the spark-plug with a spark-plug wrench. b) Check the spark-plug. Replace it if there are lots of deposits on the electrodes or if the insulator is broken or molten. Clean the spark-plug with a metal brush.

Do not sand blast the spark-plug.

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c) Measure the gap between the electrodes with thickness gauges. The gap must be between 0.7 and 0.8 mm. If an adjustment is necessary just bend the side electrode. .

d) Check if the spark-plug washer is in good condition. Then screw the spark- plug manually into position. e) Give it another 1/2 turn when installing a new spark plug or another 1/4 turn if it is a used spark-plug. Reassemble the sparkplug cap.

WARNING !!!
* Check that the spark plug is correctly tightened, if not it may overheat and damage the engine.

HANDLING, TRANSPORT AND STORAGE

1. HANDLING

To load the generator set two slings must be fixed to the frame as shown in the drawing. It is important that these slings are tightly fixed to the frame. The set is lifted by inserting a hook into the orifices in the two slings.

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2. TRANSPORT

WARNING !!!

Before carrying the generator set ensure that the knob on the engine is switched to OFF. Drain the fuel tank before carrying the generator set.

3. LONG TERM STORAGE a) Avoid storage in a damp or dusty environment. b) Drain fuel: 1. Disconnect engine fuel line and drain out fuel tank into a suitable container. If the fuel tank has a valve, turn the valve to the OPEN or ON position to drain fuel. After draining is finished, reconnect fuel line. 2. Extract cover, loosen carburettor drainage screw and drain out carburettor into a suitable container. Then tighten drainage screw and refit cover.

WARNING !!!

Petrol is highly inflammable and explosive in certain conditions. Do not smoke or allow flames or sparks nearby. c) Change engine oil. d) Extract both spark-plugs and pour a teaspoonful of motor oil into the cylinders. Crank the engine several times to spread the oil, then refit the spark-plugs. e) Remove the battery and store it in a cool, dry place. Recharge it once a month. 23

f) Cover the engine to protect from dust.

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WIRING DIAGRAMS
G 12000 H ALTERNATORS

G 12 TF H ALTERNATOR

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G 12000 H CONTROL PANEL

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G 12 TF H CONTROL PANEL

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TROUBLESHOOTING
PROBLEM
The engine does not start

PROBLABE CAUSE
1. The engine switch is in the OFF position. 2. The fuel tap is closed or the fuel tank is empty. 3. Oil sump level is too low 4. Faulty spark-plug or the gap between the electrodes is incorrect 5. Electrical appliances are connected to the outputs.

SOLUTION
1. Switch to ON 2. Open the fuel tap or add fuel 3. Fill oil sump. 4. Replace spark-plug. 5. Disconnect the appliances before starting the genset.

The engine is difficult to start or the 1. Dirty air filter 1. Change air filter engine is losing power. 2. Dirt in the fuel system or blocked fuel 2. Replace fuel filter and clean carburettor. filter 3. Blocked fuel cap vent. 3.Clean fuel tank cap. No electricity at the outputs. 1. The circuit breaker has tripped. 2. Faulty excitation. 3. Engine speed too low 4. Destroyed condenser. * 5. Faulty windings 1. Overspeed 2. Condenser capacity too high. * 1. 2. 3. 4. Speed too low Diodes or varistor destroyed Destroyed windings. Condenser capacity too low * 1. Reset. 2.Consult service technician. 3. Check engine speed. 4. Replace condenser. 5.Consult service technician. 1. Check speed 2. Check capacity. 1. Check speed. 2. Replace. 3. Check and change 4. Check and change 1. Check load. 2. Check load. 3. Check and change. 1. Check speed.

High voltage at no load

Low voltage at no load

Correct voltage without load but low 1. Speed too low with load. with load. 2. Overload 3. Shortcircuited diode. Correct voltage without load but high 1.Speed too high with load. with load. Unsteady voltage. 1. Poor contacts. 2. Unsteady speed 1. Faulty bearing. 2. Faulty coupling.

1. Check contacts. 2. Check engine regulation 1. Change. 2. Check.

Noisy alternator

* Single phase generator sets only.

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CHARACTERISTICS
ENGINE G 12000 H / G 12 TF H GX 620 614 cm3 20 HP Forced air 3000 rpm 13 litres 1.5 litres

Model Engine type Capacity Engine speed Cooling Fuel tank capacity Oil sump capacity

ALTERNATOR Rated voltage Rated frequency Sound power Lwa Maximum output power 230 / 400 V 50 Hz 100 10 000 W

DIMENSIONS AND WEIGHT Length Width Height Weight 900 mm 585 mm 510 mm 155 kg

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