Makita G1200R User manual

GENERATOR
MODEL : GI ZOOR
INSTRUCTION MANUAL
I ISSUEEMD-GU0815 I
I 3229020046 I

FOREWORD
Thank you for purchasing this portable generator. This manual contains information and
operating procedures necessary
for the effective, economical and safe operation of the
generator. For the proper operating procedures, read this manual thoroughly before
operating the generator.
For further details or questions, consult your nearest dealer.
0 Due to a constant effort to improve the product and because of a continuous program
of research and development, certain procedures, specifications and equipment are
subject to change without notice.
TABLE OF CONTENTS
....................................................
1. SAFETY PRECAUTlONS 1
2. COMPONENTlDENTlFlCATlON 3
3. CONTROLSAND INDICATORS 5
4. BEFOREOPERATION (NECESSARY INSPECTIONS/CHECKS) ............... 7
5. OPERATING PROCEDURES ...... 9
6. PERlODlC MAINTENANCE .13
7. EASY MAINTENANCE .15
8. PREPARATIONFOR STORAGE 17
9. TROUBLESHOOTlNG .18
10. APPLICABLE WATTAGE OF THE GENERATOR ........................... ..I9
11. SPEClFlCATlONS .21
12. WIRING DIAGRAM ............. .22
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1. SAFETY PRECAUTIONS
Fire prevention
0 When refueling :
- Stop the engine.
- Extreme care must be taken to prevent fire hazards.
- Be sure to fill fuel tank up to the specified level.
- Spilled fuel must bewiped off thoroughly. After
(' 8 v-
Avoid smoking and the use of matches or open flame.
Do not overfill.
spilled fuel has dried, start the engine.
0 Location of generator :
- The generator should be placed at least 1 meter (3 ft) away from buildings or other
- The surrounding area should be free of inflammables (trash, chips of wood, etc.) and
facilities.
hazardous materials (lubricants, celluloid items, explosives, etc.).
0
0 While in use :
- Be sure to operate the generator on a level surface. Avoid tilting or moving while in
operation.
-The generator should not be covered or enclosed by a box.
Prevention of electrical shock
- Never use the generator in the rain or snow.
- Never operate the generator with wet hands.
- Never spray water to clean the generator.
-1-

Exhaust gas precautions
-Exhaust gas contains toxic gases. Extreme care must be taken about people and
- Never operate the generator indoors.
- Never oprate in an enclosed area not adequately ventilated such as in a warehouse,
- The exhaust pipe should be pointed toward a well-ventilated open area.
domestic animals in the surrounding area.
tunnel, well, hold, reservoir, etc.
Necessary inspections and checks
0 Before operation (Refer to pages 7 and 8.) :
- Check oil level and refill if necessary.
- Check fuel level.
-Check the surrounding area
of the generator,
- Be sure to disconnect the load appliance.
0 Easy checking and maintenance (Refer to pages 15 and 16.)
- Attached tools.
- Air cleaner element.
- Oil change interval.
- Spark plug inspectioniadjustment.
Other safety instructions
- Never connect the generator to indoor electrical wiring. If connected, malfunctions in
- Be sure to use the generator on a level surface, never use on a soft or uneven surface
- If abnormal conditions such as excessive noise or odor or vibration appears, stop the
home electrical units or generators, fire and
/ or electric shock may result.
with small rocks, soil, gravel, etc.
engine immediately and consult your dealer for the necessary information,
-2

2. COMPONENT IDENTIFICATION
Enginecontrol switch
(CHOKE-R UN-STOP)
Muffler
I
Groundterminal Air cleaner cover
-3-

Fuel
-4-

3. CONTROLS AND INDICATORS
CHOKE
RUN
CHOKE
2”:
To start the engine, turn the knob to
this position.
(Chokevalve is closed.)
Keep the knob in this position after
the engine starts. (The engine can be
started with the knob at this position
when the engine iswarm.)
OP
CLOSE
FUEL OPEN v7
Fuel cock
\
AC receptacles
.
I\ I
00
7:” 8.3A
To stop the engine, return the knob to
this position.
1 STOP 1
Fuel Cock
0 Controlsthe supply of fuel.
CLOSE
: Enginestops.
OPEN
: Engine runs.
Voltmeter
0 Indicatesthe AC voltage output of generator
AC receptacle
0 AC electric power isavailable
through this receptacle. Use
a ground type, three-leg
plug as shown.
DCreceptacle
0 DC electric power for
battery charge isavailable.
DC receptacle
-5-

AC circuit breaker
DC circuit breaker
0 Both AC and DC circuit breakers shut off electric
current when the current exceeds its limit or a
malfunction occurs in the connected appliance.
Check for excessive current consumption or defects in
the appliance. After making sure everything is in order,
push the button to the "ON"position.
Frequency adjusting screw
0 Frequency can be finely adjusted by turning the
frequency adjusting screw with a Phillips screwdriver.
Starter handle
0 Pullthis handle to start the generator.
Ground (Earth) Terminal
0 Terminal for grounding the generator.
micircuitbreaker
[7]
I DC circuit breaker I
1 Frequency adjusting
-~ ~
i Starter handle
'\ I
Recoil starter
-I
Ground termina
-6-

4. BEFOREOPERATION (NECESSARYINSPECTIONS / CHECKS)
Oil level checking and refilling should be performed
on
a level surface with the engine stopped.
3 Oil filler neck
I/ / LEVELmark I
I
Checkingengine oil level
0 Remove oil gauge and check oil level :
- If level is low, fill to thetop of the oil filler neck.
-Change
oil if badly contaminated. (See page 15 for
Useclass
SC (API classification) oil or a higher grade of
oil.
procedure.)
SAE 1OW-30 or 1OW-40 is recommended for general,
all-temperature use.
If single viscosity oil is used, select
the appropriate viscosity for the average temperature in
your area.
SAE
1 OW-30 - For general, all temperature use
SAE 5W
- For cold weather below -1 5 "C(5"F).
Checkingfuel level
- If fuel level is low, place the engine switch to "STOP"
position.
- Refill fuel tank up to the specified level indicated by
the "LEVEL" mark in the fuel filler openings as
shown.
3.5 lit. (0.92 U.S.gal) (up to
the specified level marked
"LEVEL")
Tank capacity
I Recommendedfuel I Non-lead gasoline
I
+CAUTION
1. Take the proper precautions to prevent fire
hazards when refilling.
2. Avoid overfilling.
I 3. Besure to stop the engine before refilling.
-7-

Checking the area around the generator
- Area should befree of inflammables and hazardous materials.
- The generator is placed at least 1 meter (3 ft) away from buildings or other facilities.
- Generator is located inwell-ventilated, open area.
- The exhaust pipe is pointed toward a well-ventilated open area.
- The generator is positioned away from any type of open flame or sparks.
- The generator is placed in a stable condition on a level surface, not on an inclined or
- The generator is not enclosed or blocked by obstacles such as pieces of
uneven surface.
wood, cardboard, etc.
0 Be sure to disconnect the appliance from the generator before starting. It is very
dangerous to start the engine with the appliance on since the appliance may start
suddenly.
Check to make sure that the switch of the appliance is turned
off or its plug is discon-
nectedfrom the receptacle.
-8-

5. OPERATING PROCEDURES
Starting
- Check oil and fuel levels.
- Make sure the appliance is disconnected.
-Turn engine switch to
"CHOKE" position. (When
engine is warm or temperature is high, start engine
with the switch at "RUN" position.)
-Pull the starter handle slowly until passing the
compression point (resistance will be felt), then
return the handle to its original position and pull
swiftly.
-After starting, allow the starter handle to return to its
original positionwith the handle still in your hand.
NOTE : When engine fails to start after several
attempts, repeat the starting procedures mentioned
above with the engine switch placed at "RUN"position.
- After 20 to 30 seconds of warm-up is completed, turn
the engine switch to "RUN"position.
-9-

AC application
- Check the voltmeter for proper voltage.
The generator is thoroughly adjusted and tested in
the factory. If the generator does not produce the
specified voltage, consult your nearest Generator
dealer.
-Check the electrical appliance to see if its switch is
turned
off, then connect the appliance to the
generator.
- Switch on the appliance.
Electrical appliance
Lamp, electrical heater, radio, stereo
sets, etc.
Electrictools
e Applicable AC wattage :
The following table shows the maximum wattage of various appliances which can be
connected to the generator. Before connecting an appliance, make sure its wattage
is
within the range.
Applicable limit
60Hz
up to 1 ooow
up to about 600W
CAUTION]
1, When connecting plural appliances make sure the total wattage does not exceed
the generator's rated output. Otherwise the generator will not operate due to
excessive wattage.
2. Some power tools require a large starting current. In these cases, it may not be
possible to use the generator. Refer to page
20, or consult your dealer to obtain the
necessary information.
3. When overloaded, the AC circuit breaker pops out to cut off the current. In such a
case, make sure that the applied wattage of the appliance has not exceeded the
wattage limit and that there are no defects in the appliance. Then push the circuit
breaker back into the "ON"position.
- 10 -

I I
I DC receptacle I
o Grounding the generator
-To ground the generator to the earth, connect the
grounding lug of the generator to the gounding spike
driven into the earth or to the conductor which has
been already grounded to the earth.
- If such grounding conductor or grounding electrode
is unavailable, connect the grounding lug of the
generator to the grounding terminal of the using
electric tool or appliance.
CAUTION
Generator must be grounded when the electrical
appliance
is grounded.
Failure to ground generator may lead to electric
shock.
DC application (For charging 12V battery only)
0 DC receptacle is used only for charging a 12V
battery.
0 Connection of battery charging cables :
Using the attached DC plug, connect its positive and
negative terminals to the corresponding battery
terminals.
0 Battery charging procedures :
- Makethe proper connection as mentioned above, be
careful not to make a wrong connection. Be sure to
disconnect all cables connected from battery to any
other appliance.
- Removeall plugs from top of battery.
- Check electrolyte level and add distilled water if
necessary, to bring the electrolyte level to the level
marked
"UPPER".
- Start engine to charge battery.
The charging time varies depending on the condition of
-.
discharge. The specific gravity of a battery electrolyte indicates the state of charge in
each battery cell. While charging battery, check the specific gravity with a hydrometer,
using a thermometer to correct hydrometer reading for temperature.
A corrected specific
gravity reading of 1.26to 1.28 in all cells indicates a fully charged battery.
Example : In case of 12V-40Ah automobile battery, it takes 5 to 6 hours to bring a
completely discharged battery to a state of full-charge.
- 11 -

0 Charging safety :
Batteries produce explosive hydrogen gas. This gas is emitted from the vent hole of each
battery cap. Safety precautions must be observed to prevent ignition and subsequent
explosion
of the hydrogen gas caused by open flame or sparks.
- No smoking and open flame near a charging battery.
- Be sure to performthe battery charging operation in a well-ventilated area.
Extreme care must betaken as electrolyte will burn eyes, skin and clothing. If injured, use
a large quality of water to clean the affected area immediately, then consult
a doctor for
medical treatment.
CAUTION]
1. When charging a large capacity battery, DC output will exceed the limit and the
DC circuit breaker will pop out to the
"OFF" position. In such a case, push DC circuit
breaker into the
"ON" position after checking the battery.
i 2. Do not use DC and AC output simultaneously.
.---
Stopping generator
Proceed as follows :
- Turn off electrical appliance switch and disconnect
cable from receptacle.
-Turn engine switch to
"STOP" position
- 12 -

6. PERIODIC MAINTENANCE
Fuel level
Proper maintenance of the generator will allow reliable performance and reasonable
maintenance cost. This section outlines
a standard schedule for this purpose. This
schedule should beadjusted as necessary to conform to the owner's conditions
of use.
Condition of engine Air cleaner Bolts and nuts
oil and level
- element for looseness
-E
Leakage of
gasoline or oil -
Easy maintenance
Every 50 hours
Every
100 hours Change oil.
Every
6 months
(200 hours)
See page
15 for detailed information.
Wash cleaner element (or everyday when operating in extremely
dusty conditions.), clean spark plug.
Adjust spark plug gap.
Connection of Surrounding Noise or
appliance
-- area - vibration level
Draw up the most convenient schedule for conducting required checks, on the basis of
the maintenance schedule outlined on the next page.
PERIODIC MAINTENANCE (UNDER NORMAL OPERATING
CONDITIONS)
Every 6 months
(200 hours)
Every
12 months
(500 hours)
Every
24 months
(1,000 hours) Replace engine mount,overhaul.
Clean fuel filter.
Replace spark plug and cleaner element, clean
/ adjust carburetor,
cyl. head, valve clearance, valve seat and engine switch.
Inspect control panel parts, rotor and stator.
1. Change fuel lines if any leakage isfound or after every two years regardless of usage.
2. Overhauling includes checking dimensions and adjusting or replacing component parts
according to Repair Standards inthe Service Manual.
It is recommendedthat the generator be overh,auledevery 2 years(1,OOO hours).
For USA only
: Clean spark arrester.
- 13 -

MAINTENANCE SCHEDULE
Do-it-yourselfservice
Check & add engine oil
Clean air cleaner
I Item I Interval I
.... refill as required
Check before each use
Change engine
oil
Adjust spark plug gap
I Clean & retighten screws I I
Every 100 hours (initial : after 20 hours)
Every
6 months (200 hours)
Wash cleaner element
Clean spark plug
Every
50 hours
Every
50 hours See page 15.
Periodic maintenance
Item
_____
Clean fuel filter
Change spark plug
Clean carburetor
Removecarbon from cyl. head
Check
& adjust valve clearance
Overhaul
Check engine switch
Check rotor
Check stator
Change engine mount
Control panel parts
AC receptacle
DC receptacle
Circuit breaker
Every
6
months
(200 hours)
#
Every 12
months
(500 hours)
#
Every 24
months
(1,000 hours)
- 14 -

7. EASY CHECKING AND MAINTENANCE
Q? o I
Drain plug
Air cleaner servicing
0 If the air cleaner element is clogged, a decrease in
generator output, erratic engine operation and
/ or
excessive fuel consumption may result. Be sure to
clean air cleaner periodicallyas follows
:
Interval : Every 50 hours or clean every day (or
every
10 hours) when operating in extremely dusty
conditions.
Cleaning procedure
-Using a coin, loosen screw securing air cleaner
cover in placeand removecover.
-Remove element and clean with fresh cleaning
solvent.
-After cleaning, soak element in a clean fuel mixture
(3 parts gasoline to 1 part engine oil), then squeeze
out excess oil and reinstall.
1. Extreme care must be taken to prevent fire
especially when cleaningair cleaner element.
2. When squeezing excess oil out of element, do
nottwist element,just grasp and squeeze it tightly.
Engine oil change
0 Servicingperiod :
- Initial servicing : 20 hours after initial operation.
- Regular servicingperiod : Every 100 hours.
0 Drain oil by removing the drain plug and the oil filler
cap whilethe engine is warm.
0 Reinstallthe drain plug and refill with fresh oil up to
the upper level mark on the oil gauge.
0 Usefresh and high quality oil as specifiedin page 7.

Checkingthe spark plug
0 Inspection and adjustment procedure :
- Open spark plug cover.
-Remove plug cap and remove spark plug using a
plug wrench.
-Using plug cleaner or wire brush, clean plug elec-
trode of burnt or deposited carbon.
- Check for proper gap between electrodes. Adjust
gap to
0.6 to 0.7 mm (0.02 to 0.03 in) by bending the
side electrode if necessary.
(make : NGK).
- Recommended replacement plug type : BR6HS
AL 0.6-0.7 mm
(0.02-0.03 in)
Spark arrester cleaning
0 Inspect the spark arrester every 50 hours for carbon
deposit or damage.
Clean or replace if necessary.
1. Make sure that the muffler is cool before working.
2. Removethe spark arrester and inspect.
3. Use a wooden scraper or small wire bursh to scrape
away any dirt or carbon deposits from exhaust outlet
opening and spark arrester screen.
4. Reinstall spark arrester screen.
Cleaning fuel strainer
0 Check for water or contaminants in the fuel strainer.
0 To remove contaminants, close fuel cock and re-
move strainer cup.
0 After removing contaminants and water, wash the
cup and strainer with gasoline, Reinstall securely to
prevent leakage.
~iug cover
7.
I Spark arrester
I
I-
\
- 16 -

8. PREPARATION FOR STORAGE
- Removefuel strainer cup, open fuel cock and completely drain fuel from tank.
-After draining fuel, reinstall strainer cup and close the fuel cock.
-Start and run the generator without an appliance connected until the carburetor is
completely empty of fuel.
- Change old lubricating oil with fresh oil.
- Clean air cleaner element.
- Remove spark plug and pour 5-10 cc (1 fl.oz.) of lubricating oil through the plug hole.
Then pull starter handle several times and reinstallthe spark plug.
- Checkfor loose bolts and nuts. Retighten if necessary.
- Clean generator throughly and spray completely with a preservative spray if available.
- Besure to place engine switch at the "STOP" position.
- Pull starter handle until resistance is felt and leave it in that position.
- Storage indoors in a well-ventilated, low humidity area is recommended.
CAUTION]
Extreme care must be taken when draining fuel tank. Never use water to clean the
generator.
- 17 -