Smarter tools ST-GP1200 User manual

Owner’s Manual
ST-GP1200
WARNING! To Reduce Risk of Injury,
User Must Read and Understand
Owner’s Manual Prior to Use.
NOTE: Retain Original Sales Receipt as Proof of Purchase!

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©2009 Smarter Tools, Inc. All Rights Reserved
ST-GP1200
1200W Generator
Table of Contents
Introduction .............................................................. 03
Safety Guidelines – Definitions .............................. 04
General Precautions ................................................ 05
Carbon Monoxide.......................................... 05
Gasoline and Oil............................................ 05
Hot Components ........................................... 06
Power Output ................................................ 06
Work Area ..................................................... 06
Electrical Safety ............................................ 07
Personal Safety............................................. 07
General Use and Care.................................. 08
Servicing........................................................ 08
Installation..................................................... 09
Mechanical.................................................... 09
Chemicals...................................................... 10
Noise ............................................................. 10
Extension Cords............................................ 10
Controls and Features............................................. 11
Generator...................................................... 11
Control Panel ................................................ 12
Installation ................................................................ 13
General Location........................................... 13
Support and Mounting................................... 14
Grounding...................................................... 14
Add Engine Oil .............................................. 14
Add Fuel........................................................ 14
Operation .................................................................. 15
Starting.......................................................... 15
Surge Protection ........................................... 15
Capacity ........................................................ 15
Power Management...................................... 16
Connecting Electrical Loads.......................... 16
Stopping the Engine...................................... 16
Wattage Reference Guide ........................................17
Your Power Needs.........................................17
Inspection, Cleaning, and Maintenance .................18
Changing Oil..................................................18
Spark Plug .....................................................19
Air Filter..........................................................19
Spark Arrester (optional)................................19
Cleaning.........................................................19
Maintenance Schedule..................................19
Storage ..........................................................20
Transporting...................................................20
Specifications............................................................21
Parts Lists..................................................................22
Crankcase Assembly.....................................22
Crankcase Cover Assembly ..........................22
Crankshaft Assembly.....................................22
Cylinder Head Assembly ...............................23
Air Filter Assembly.........................................24
Piston & Connecting ......................................24
Carburetor Assembly.....................................24
Centrifugal Assembly.....................................24
Flywheel Assembly........................................25
Starter Assembly............................................25
Generator Assembly......................................26
Gas Tank .......................................................26
Control Panel Assembly ................................27
Muffler............................................................27
Frame Assembly............................................27
Troubleshooting........................................................28
Warranty Identification.............................................29
Limited Warranty.......................................................30
WARNING!
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS IN THIS MANUAL BEFORE OPERATING.
FAILURE TO COMPLY WITH INSTRUCTIONS IN THIS MANUAL COULD RESULT IN PERSONAL
INJURY, PROPERTY DAMAGE, AND/ OR VOIDING OF YOUR WARRANTY. SMARTER TOOLS WILL
NOT BE LIABLE FOR ANY DAMAGE BECAUSE OF FAILURE TO FOLLOW THESE INSTRUCTIONS.

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©2009 Smarter Tools, Inc. All Rights Reserved
1200W Generator
Introduction
_________________________________________________________________________________________________
Congratulations on your purchase of a Smarter Tools
generator. Smarter Tools designs and builds generators
to strict specifications. With proper use and maintenance,
this generator will bring years of satisfying service.
Portable Power Generator
This unit is an electric start, gasoline engine driven,
alternating current (AC) generator. It is designed to
supply electrical power for lighting, appliances, tools
and similar equipment.
This Booklet
Every effort has been made to ensure the accuracy
and completeness of the information in this manual.
We reserve the right to change, alter and/or improve
the product and this document at any time without prior
notice. For the most up to date information regarding
your Smarter Tools product please visit us at
www.usesmartertools.com
Record the model and serial numbers as well as date and place of purchase for future reference.
Have this information available when ordering parts and when making technical or warranty inquiries.
Smarter Tools Customer Service
1-804-798-8588
Model Number
GP1200
Serial Number
Date of Purchase
Purchase Location

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©2009 Smarter Tools, Inc. All Rights Reserved
Owner’s Manual
Safety Guidelines - Definitions
_________________________________________________________________________________________________
This manual contains important information that you need to know and understand in order to assure YOUR SAFETY and
PROPER OPERATION OF EQUIPMENT. The following symbols help you recognize this information. Please read the
manual and pay attention to these sections.
Save These Important Safety Instructions!
Read and understand all of these safety instructions. Be sure to retain them for future use.
WARNING!
WARNINGS INDICATE A CERTAINTY OR STRONG POSSIBILITY OF PERSONAL INJURY OR
DEATH IF INSTRUCTIONS ARE NOT FOLLOWED.
CAUTION:
CAUTIONS INDICATE A POSSIBILITY OF EQUIPMENT DAMAGE IF INSTRUCTIONS ARE NOT
FOLLOWED PROPERLY.
Note: Notes give helpful information.
WARNING!
IMPROPER OPERATION OR MAINTENANCE OF THIS PRODUCT COULD RESULT IN SERIOUS
INJURY AND PROPERTY DAMAGE. READ AND UNDERSTAND ALL WARNINGS AND OPERATING
INSTRUCTIONS BEFORE USING THIS EQUIPMENT. BASIC SAFETY PRECAUTIONS SHOULD
ALWAYS BE FOLLOWED TO REDUCE THE RISK OF PERSONAL INJURY.
Save These Important Safety Instructions!
Read and understand all of these safety instructions. Be sure to retain them for future use.

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©2009 Smarter Tools, Inc. All Rights Reserved
Owner’s Manual
General Safety Precautions
_________________________________________________________________________________________________
WARNING!
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SEVERE INJURY OR DEATH.
CAUTION:
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN ALSO RESULT IN DAMAGE TO THE EQUIPMENT
AND/OR THE ITEM YOU ARE WORKING ON OR WITH.
Carbon Monoxide
•Carbon Monoxide is an odorless and colorless gas. Breathing exhaust that contains this poisonous gas can cause
unconsciousness and may lead to death.
•The engine exhaust from this product contains chemicals recognized by the state of California to cause cancer,
birth defects, or other reproductive harm.
•When this tool is running, ensure that the area is well ventilated. Never run the engine in an enclosed area. Run
the engine in an open area or with an exhaust evacuation system in an enclosed area.
•NEVER use a generator inside homes, garages, crawlspaces, or other partially enclosed areas. Deadly levels of
carbon monoxide can build up in these areas. Using a fan or opening windows and doors does NOT supply
enough fresh air.
•ONLY use a generator outdoors and far away from open windows, doors, and vents. These openings can pull in
generator exhaust.
•Even when you use a generator correctly, CO may leak into the home. ALWAYS use a battery-powered or
battery-backup CO alarm in the home.
•If you start to feel sick, dizzy, or weak after the generator has been running, move to fresh air RIGHT AWAY. See
a doctor. You could have carbon monoxide poisoning.
WARNING!
THE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS THAT CAN CAUSE LOSS OF
CONSCIOUSNESS AND MAY LEAD TO DEATH.
Gasoline and Oil
This product requires oil and fuel. THE ENGINE WILL NOT START WITHOUT OIL. Work in well ventilated area. Keep
cigarettes, flames or sparks away from the work area or where gasoline is stored.
WARNING!
GASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS. KEEP
OUT OF REACH OF CHILDREN.

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©2009 Smarter Tools, Inc. All Rights Reserved
Owner’s Manual
General Safety Precautions (cont’d)
_________________________________________________________________________________________________
Gasoline and Oil (cont’d)
•Gasoline fuel and fumes are flammable and potentially explosive. Use proper fuel storage and handling
procedures. Always have multiple ABC class fire extinguishers nearby.
•Keep the generator and surrounding area clean at all times. Keep the generator at least 5 feet away from
buildings and other equipment during operation.
•Fuel or oil spills must be cleaned up immediately. Dispose of fluids and cleaning materials as per any local, state,
or federal codes and regulations. Store oily rags in a covered metal container.
•Never store fuel or other flammable materials near the generator.
•Do not smoke, or allow sparks, flames or other sources of ignition around the engine and fuel tank. Fuel vapors
are explosive.
•Keep grounded conductive objects, such as tools, away from exposed, live electrical parts and connections to
avoid sparking or arcing. These events could ignite fumes or vapors.
•Do not refill the fuel tank while the engine is running or while the engine is still hot. Do not operate the generator
with known leaks in the fuel system.
•Excessive buildup of unburned fuel gases in the exhaust system can create a potentially explosive condition. This
buildup can occur after repeated failed start attempts, valve testing, or hot engine shutdown. If this occurs, open
exhaust system drain plugs, if equipped, and allow the gases to dissipate before attempting to restart the generator.
•Use only engine manufacturer recommended fuel and oil.
Hot Components
WARNING!
HOT EXHAUST CAN BURN YOU. ENGINE AND EXHAUST SYSTEM PARTS BECOME VERY HOT AND
REMAIN HOT FOR SOME TIME AFTER THE ENGINE IS RUN. WEAR INSULATED GLOVES OR WAIT
UNTIL THE ENGINE AND EXHAUST SYSTEM HAVE COOLED BEFORE HANDLING THESE PARTS.
Power Output
This generator is not designed to power sensitive electronic equipment (including computers and medical devices) without
the addition of an approved line conditioner, which is sold separately.
CAUTION:
ATTEMPTING TO POWER SENSITIVE ELECTRONIC EQUIPMENT WITHOUT THE USE OF AN
APPROVED LINE CONDITIONER MAY CAUSE DAMAGE TO THE EQUIPMENT.
Work Area
•Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents.
•Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or
dust. Generators create sparks which may ignite the dust or fumes.
•Keep bystanders, children, and visitors away while operating a generator. Provide barriers or shields as needed.

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©2009 Smarter Tools, Inc. All Rights Reserved
Owner’s Manual
General Safety Precautions (cont’d)
_________________________________________________________________________________________________
Electrical Safety
•Keep all electrical equipment clean and dry. Replace any wiring where the insulation is cracked, cut eroded part
or otherwise degraded. Replace terminals that are worn, discolored, or corroded. Keep terminals clean and tight.
•Insulate all connections and disconnected wires.
•Do not abuse the power cord. Keep power cords away from heat, oil, sharp edges, or moving parts. Replace
damaged power cords immediately. Damaged power cords increase the risk of electric shock.
•Do not operate the generator with wet hands. Do not expose generator to rain, snow or wet conditions. Water will
increase the risk of electric shock. The generator is a potential source of electrical shock if not kept dry.
•Do not attempt to connect or disconnect load connections while standing in water, or on wet or soggy ground.
•Do not touch electrically energized parts of the generator and interconnecting cables or conductors with any part
of the body, or with any non-insulated conductive object.
•Avoid body contact with grounded surfaces such as pipes, radiators, ranges, and refrigerators. There is an
increased risk of electric shock if your body is grounded.
•When operating a power tool outside, use an outdoor extension cord marked “W-A” or “W”. These extension
cords are rated for outdoor use, and reduce the risk of electric shock.
•Grounded tools must be plugged into an outlet properly installed and grounded in accordance with all codes and
ordinances. Never remove the grounding prong or modify the plug in any way. Do not use any adapter plugs.
•Double insulated tools are equipped with a polarized plug where one blade is wider than the other. This plug fits in
a polarized outlet only one way. If the plug does not fit fully in the outlet, reverse the plug. If it still does not fit,
contact a qualified electrician to install a polarized outlet. Do not change the plug in any way. Double insulation
eliminates the need for the three-wire grounded power cord and grounded power supply system.
•Before servicing equipment powered by the generator, disconnect the equipment from its power input.
•The generator must be earth-grounded for fixed installations in accordance with all relevant electrical codes and
standards before operation.
•Grounding provides a low-resistance path to carry electricity away from the user in the event of an electrical
malfunction.
•All connections and conduits from the generator to the load must only be installed by trained and licensed
electricians and in compliance with all relevant local, state, and federal electrical codes and standards, and other
regulations where applicable.
•Connect the generator only to a load or electrical system (110/120 volt) that is compatible with the electrical
characteristics and rated capacities of the generator.
•NEVER try to power building or home wiring by plugging the generator into a wall outlet, a practice known as
“backfeeding.” This is extremely dangerous and presents an electrocution risk to utility workers and neighbors
served by the same utility transformer. It also bypasses some of the built-in household circuit protection devices.
Personal Safety
CAUTION:
DO NOT SIT, STAND, OR PLACE OBJECTS ON TOP OF THE GENERATORS FUEL TANK.
REGARDLESS OF WHETHER IT IS RUNNING OR NOT.
•Stay alert. Watch what you are doing, and use common sense when operating a generator. Do not use generator
while tired or under the influence of drugs, alcohol, or medication. A moment of inattention while operating
generators may result in serious personal injury.
•Make note of the location of the engine power switch should you need to turn off the generator quickly.
•Dress properly. Contain long hair, clothing, jewelry, and gloves as they can be caught in moving parts.
•Avoid accidental starting. Make sure the power switch is in its “OFF” position, and disconnect the spark plug wire
when not in use.

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©2009 Smarter Tools, Inc. All Rights Reserved
1200 Generator
General Safety Precautions (cont’d)
_________________________________________________________________________________________________
Personal Safety (cont’d)
•Remove adjusting keys or wrenches before turning the generator on. A wrench or a key that is left attached to a
rotating part of the generator may result in personal injury.
•Do not overreach. Keep proper footing and balance at all times.
•Use safety equipment. Always wear eye protection. Wear ANSI approved safety impact eye goggles. Dust mask,
non-skid safety shoes, safety gloves, hard hat, or hearing protection must be used for appropriate conditions.
•Do not use the generator if the power switch does not turn it on or off. Any generator
that cannot be controlled with the power switch is dangerous and must be replaced.
•Do not force the generator. Use the correct generator for your application. The correct
generator will do the job better and safer at the rate for which it is designed.
•The generator weighs 54 lbs. Two or more people should assist when moving or lifting this product. Never lift the
Generator using the engine or alternator lifting lugs. Connect lifting equipment to the Frame of the generator.
Generator Use and Care
•Make sure the power switch is in its “OFF” position and disconnect the spark plug wire before making any
adjustment, changing accessories, or storing the generator. Such preventive safety measures reduce the risk of
starting the generator accidentally.
•Store idle generators out of reach of children and other untrained persons. Generators are dangerous in the
hands of untrained users.
•Maintain generators with care. Do not use a damaged generator. Tag damaged generators “Do not use” until
repaired.
•Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the
generator’s operation. If damaged, have the generator serviced before using. Many accidents are caused by
poorly maintained generators.
•Use only accessories that are recommended by the manufacturer for your model. Accessories that may be
suitable for one generator may become hazardous when used on another generator.
Servicing
•Maintain labels and name plates on the generator and engine. These carry important information. If unreadable or
missing, contact Smarter Tools immediately for a replacement.
•Generator service must be performed only by qualified repair personnel. Service or maintenance performed by
unqualified personnel could result in a risk of injury.
•When servicing a generator, use only identical replacement parts. Follow all appropriate instructions in this
manual. Use of unauthorized parts or failure to follow maintenance instructions may create a risk of electric shock
or injury.
WARNING!
PEOPLE WITH PACEMAKERS SHOULD CONSULT THEIR PHYSICIAN(S) BEFORE USING THIS
PRODUCT. ELECTROMAGNETIC FIELDS IN CLOSE PROXIMITY TO A HEART PACEMAKER COULD
CAUSE INTERFERENCE TO OR FAILURE OF THE PACEMAKER.

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©2009 Smarter Tools, Inc. All Rights Reserved
Owner’s Manual
General Safety Precautions (cont’d)
_________________________________________________________________________________________________
Installation
•Ensure installation meets all applicable safety, and local and national electrical codes. Have installation performed
by a qualified, licensed electrician and building contractor.
•All electrical work, including the earth-ground connection, should be completed by a licensed electrician.
•Any separate fuel storage or generator supply facility must be built or installed in full compliance with all relevant
local, state, and federal regulations.
•It is recommended to use the generator only in well ventilated outdoor areas. A running gasoline engine will
generate carbon monoxide, a colorless, odorless gas that, if inhaled, can cause serious injury or death. If the
generator is installed indoors, exhaust fumes must be piped out of the building using leak-free, heat resistant
piping. Pipes and silencer should not use any flammable materials, nor should they be installed near the same.
Generator exhaust fumes must be within legal limits and installation must always meet local building codes.
•If the generator is installed outdoors, it must be weatherproofed and should be soundproofed. It should not be run
outdoors without protection of the generator and wiring conduit.
•Two or more people should assist when moving or lifting this product. Never lift the Generator using the engine or
alternator lifting lugs. Connect lifting equipment to the Frame of the generator.
•Before lifting the generator, ensure the lift rigging and supporting structure are in good condition, and are rated to
lift such a load.
•Keep all personnel away from the suspended generator during relocating.
•The supporting floor/ground surface should be level, and strong enough to safely hold the weight of the generator.
If the floor/grounded surface is not level, strong cross members should be placed under the full length of the
generator frame at its low side.
•For trailer installation, the generator should be mounted on the center point of the trailer, over the wheels. The
trailer must be capable of supporting the weight of the generator and all contents (tools, etc.)
•Install sound-and weather-proofing only when it is not raining or snowing to avoid trapping moisture within the
generator’s area.
Mechanical
•Always make sure the power switch is in its “OFF” position. Disconnect the spark plug wire, and allow the engine
to completely cool before carrying out maintenance.
•Check for damaged parts. Before using the generator, any part that appears damaged should be carefully
checked to determine that it will operate properly and perform its intended function. Check for alignment and
binding of moving parts, any broken parts or mounting fixtures, and any other condition that may affect proper
operation technician.
•The generator is designed with guards for protection from moving parts. In any case, care must still be taken to
protect personnel and equipment from other mechanical hazards when working around the generator.
•Do not operate the generator with safety guards removed. While the generator is running, do not attempt to reach
around the safety guard for maintenance or any other reason.
•Keep hands, arms, long hair, loose clothing, and jewelry away from moving parts. Be aware that when engine
parts are moving fast they cannot be seen clearly.
•Keep access doors on enclosures closed and locked when access is not required.
•When working on or around the generator always wear protective clothing including ANSI approved safety gloves,
safety eye goggles, and safety hat.
•Do not alter or adjust any part of the generator that is assembled and supplied by the manufacturer.
•Always follow and complete scheduled engine and generator maintenance.

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©2009 Smarter Tools, Inc. All Rights Reserved
Owner’s Manual
General Safety Precautions (cont’d)
_________________________________________________________________________________________________
Chemicals
•Avoid contact with hot fuel, oil, exhaust fumes, and hot solid surfaces.
•Avoid body contact with fuels, oils, and lubricants used in the generator. If swallowed, seek medical treatment
immediately. Do not induce vomiting if fuel is swallowed. For skin contact, immediately wash with soap and water.
For eye contact, immediately flush eyes with clean water and seek medical attention.
Noise
Prolonged exposure to noise levels above 85dBA is hazardous to hearing.
Always wear ANSI approved ear protection when operating or working around the Generator when it is running.
Extension Cords
If an extension cord (not included) is used, make sure to use only UL approved cords having the correct gauge and length
according to the following table:
Nameplate Amps Cord Lengths
(@full load)
0”-50” 50”-100” 100”-150” 150”-200”
0-5 16 16 12 12
5.1-8 16 14 10 -
8.1-12 14 12 - -
12.1-15 12 10 - -
15-20 10 10 - -