GENERATOR

MODEL

:

GI Z O O R

INSTRUCTION MANUAL

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ISSUE EMD-GU0815

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3229020046

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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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. COMPONENTlDENTlFlCATlON

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3. CONTROLSAND INDICATORS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

3

5

4.

5.

BEFORE OPERATION (NECESSARY INSPECTIONS /CHECKS)

OPERATING PROCEDURES . . . . . .

. . . . . . . . . . . . . . .

7

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9

6. PERlODlC MAINTENANCE

7 . EASY MAINTENANCE

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.13

.15

8.

9.

PREPARATION FOR STORAGE

TROUBLESHOOTlNG

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17

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10. APPLICABLE WATTAGE OF THE GENERATOR

11. SPEClFlCATlONS

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12. WIRING DIAGRAM

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1. SAFETY PRECAUTIONS

facilities.

Fire prevention

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When refueling :

Avoid smoking and the use of matches or open flame.

Do not overfill. off thoroughly. After spilled fuel has dried, start the engine.

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Location of generator : hazardous materials (lubricants, celluloid items, explosives, etc.).

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While in use : operation.

-The generator should not be covered or enclosed by a box.

Prevention of electrical shock

- 1 -

Exhaust gas precautions

-Exhaust gas contains toxic gases. Extreme care must be taken about people and domestic animals in the surrounding area. tunnel, well, hold, reservoir, etc.

Necessary inspections and checks

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Before operation (Refer to pages 7 and :

-Check the surrounding area of the generator,

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Easy checking and maintenance (Refer to pages 15 and 16.)

Other safety instructions 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 in

2.

COMPONENT IDENTIFICATION

Engine control switch

(CHOKE-R UN-STOP)

Ground terminal

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Air cleaner cover

Muffler

- 3 -

Fuel

- 4 -

3.

CONTROLS AND INDICATORS

2”:

CHOKE

OP

CHOKE

To start the engine, turn the knob to this position.

(Choke valve is closed.)

RUN

Keep the knob in this position after the engine starts. (The engine can be started with the knob at this position

1

STOP

1 when the engine is warm.)

To stop the engine, return the knob to this position.

CLOSE

Fuel Cock

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Controls the supply of fuel.

CLOSE : Engine stops.

OPEN : Engine runs.

Fuel cock

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Voltmeter

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Indicates the AC voltage output of generator

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7:”

8.3A

DC receptacle

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AC electric power is available a ground type, three-leg plug as shown.

DC receptacle

0 DC electric power for battery charge is available.

- 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. m i c i r c u i t breaker 7

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DC circuit breaker

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Frequency adjusting screw

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Frequency can be finely adjusted by turning the frequency adjusting screw with a Phillips screwdriver.

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Frequency adjusting

Starter handle

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Pull this handle to start the generator.

Ground (Earth) Terminal

0 Terminal for grounding the generator.

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Starter handle

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-I Recoil starter

Ground termina

- 6 -

4.

BEFORE OPERATION (NECESSARY INSPECTIONS

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CHECKS)

Checking engine oil level

0 Remove oil gauge and check oil level :

-Change oil if badly contaminated. (See page 15 for procedure.)

Use class SC (API classification) oil or a higher grade of oil.

3

Oil filler neck

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 -

SAE 5W For cold weather below -1 5 "C(5"F).

Oil level checking and refilling should be performed on a level surface with the engine stopped.

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LEVELmark

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Checking fuel level position. the "LEVEL" mark in the fuel filler openings as shown.

Tank capacity

3.5 lit. (0.92 U.S.gal) (up to the specified level marked

"LEVEL")

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Recommended fuel

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Non-lead gasoline

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1 . Take the proper precautions to prevent fire

2. Avoid overfilling.

- 7 -

Checking the area around

the

generator

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1 meter (3 ft) away from buildings or other facilities. is positioned away from any type of open flame or sparks. uneven surface. wood, cardboard, etc.

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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- nected from the receptacle.

- 8 -

5. OPERATING PROCEDURES

Starting

-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 position with 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.

- of warm-up is completed, turn the engine switch to "RUN" position.

- 9 -

AC application

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, generator. then connect the appliance to the 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.

Electrical appliance

Lamp, electrical heater, radio, stereo sets, etc.

Electric tools

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.

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DC receptacle

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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. 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)

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DC receptacle is used only for charging a 12V battery.

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Connection of battery charging cables :

Using the attached DC plug, connect its positive and negative terminals to the corresponding battery terminals.

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Battery charging procedures : careful not to make a wrong connection. Be sure to disconnect all cables connected from battery to any other appliance. necessary, to bring the electrolyte level to the level marked "UPPER". 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 1.26 to 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.

Extreme care must be taken 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.

Stopping generator

Proceed as follows :

DC circuit breaker will pop out to the "OFF" position. In such a case, push DC circuit

2.

DC output will exceed the limit and the

CAUTION]

1. i

When charging a large capacity battery, breaker into the "ON" position after checking the battery.

Do not use DC and AC output simultaneously. .--- off electrical appliance switch and disconnect cable from receptacle.

-Turn engine switch to "STOP" position

- 12 -

6.

PERIODIC MAINTENANCE

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 be adjusted as necessary to conform to the owner's conditions of use.

Fuel level

-E

Condition of engine oil and level

- element

Bolts and nuts for looseness

Leakage of gasoline or oil

- appliance

Surrounding

-- area

- vibration level

Easy maintenance

Every 50 hours Wash cleaner element (or everyday when operating in extremely dusty conditions.), clean spark plug.

Every 100 hours

Every 6 months

(200 hours)

Change oil.

Adjust spark plug gap.

See page 15 for detailed information.

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)

Clean fuel filter. Every 6 months

(200 hours)

Every 12 months

(500 hours)

Every 24 months

(1,000 hours)

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.

Replace engine mount,overhaul.

1. Change fuel lines if any leakage is found or after every two years regardless of usage.

2. Overhauling includes checking dimensions and adjusting or replacing component parts according to Repair Standards in the Service Manual.

It is recommended that the generator be overh,auled every 2 years(1,OOO hours).

For USA only : Clean spark arrester.

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MAINTENANCE SCHEDULE

Do-it-yourself service

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Item

Check & add engine oil

Clean air cleaner

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Clean & retighten screws

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Wash cleaner element

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Clean spark plug

Change engine oil

Adjust spark plug gap

Interval

.... refill as required

Check before each use

Every 50 hours

Every 50 hours See page 15.

Every 100 hours (initial : after 20 hours)

Every 6 months (200 hours)

Periodic maintenance

Every 6 months

(200 hours)

#

Every 12 months

(500 hours)

Every 24 months

(1,000 hours)

Item

_____

Clean fuel filter

Change spark plug

Clean carburetor

Remove carbon 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

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7.

EASY CHECKING AND MAINTENANCE

Air cleaner servicing

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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 periodically as follows :

Interval : Every 50 hours or clean every day (or every 10 hours) when operating in extremely dusty conditions.

Q?

Drain plug

Cleaning procedure

-Using a coin, loosen screw securing air cleaner cover in place and remove cover.

-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 cleaning air cleaner element.

2. When squeezing excess oil out of element, do not twist element, just grasp and squeeze it tightly.

Engine oil change

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Servicing period :

: 20 hours after initial operation.

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: Every 100 hours.

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Drain oil by removing the drain plug and the oil filler cap while the engine is warm.

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Reinstall the drain plug and refill with fresh oil up to the upper level mark on the oil gauge.

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Use fresh and high quality oil as specified in page 7.

Checking the spark plug

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Inspection and adjustment procedure :

-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. gap to 0.6 to 0.7 mm (0.02 to 0.03 in) by bending the side electrode if necessary.

: BR6HS

(make : NGK).

7.

AL

0.6-0.7 m m

(0.02-0.03 in)

Spark arrester cleaning

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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. Remove the 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

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Check for water or contaminants in the fuel strainer.

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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.

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Spark arrester

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8.

PREPARATION FOR STORAGE

-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.

- 5-10 cc (1 fl.oz.) of lubricating oil through the plug hole.

Then pull starter handle several times and reinstall the spark plug.

- if necessary.

Be sure to place engine switch at the "STOP" position.

Pull starter handle until resistance is felt and leave it in that position.

CAUTION]

Extreme care must be taken when draining fuel tank. Never use water to clean the generator.

- 17

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When engine fails to start or if the engine turns but there is no electricity at the receptacles, perform the following checks.

When engine fails to start : proper position.

Place engine switch to "CHOKE" position to start engine. ("RUN" position when starting a warm engine.)

If closed,open fuel cock.

Check fuel level.

Check to make sure that the generator is not connected to

If empty, refill fuel tank. - off the power switch on the connected appliance or disconnect power cable. an appliance.

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Check spark plug for loose plug cap.

Be sure to press spark plug cap securely.

I contamination.

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Remove spark plug and clean electrode.

When no electricity

is

generated at receptacle :

Check AC or DC circuit breaker if it is at the normal operating "ON" position.

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After making sure that the total wattage of the electrical appliance is within permissible limits and there are no defects in the electrical appliance, push AC or DC circuit breaker back into "ON" position.

I receptacle for loose connections.

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Check if engine starting was attempted with the electrical appliance connected.

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Secure connection, if necessary.

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Turn off switch of the electrical appliance or

I disconnect plug from receptacle and after the generator is in a stable condition, make the connection again.

* If engine still does not start, contact your dealer for further infomation.

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IO.

APPLICABLE WATTAGE

OF

THE GENERATOR

Electric appliances normally come with a label indicating voltage, cycle and (input) wattage, the electric power which the appliance consumes. However, when the generator is used as the power source both power factor and starting current should be considered.

HEATING RESISTANCE (Power factor 1

.O,

No starting current)

Electrical loads such as incandescent lamps and hot plates require the same wattage as indicated on the label.

Example : A 1 kW generator can power ten 1 OOW lamps.

ELECTRIC DISCHARGE TUBE (Power factor less than

1 .O,

Discharge starting valtage is required.)

Loads such as fluorescent lamps and mercury lamps require 1.2 to 2 times the stated wattage to start discharge.

Example : A 1 kW generator can power three to seven 80W mercury lamps.

ELECTRIC MOTOR (Power factor less than

1.0,

Starting current is required.)

Electric motors require large starting wattage. Its power requirement depends on kind and circumstance.

Electric tool (Driven by commutator motor, Shaft free in starting)

It speeds up quickly in starting, that is,it requires 1.2 to 3 times its wattage for starting.

Example : A 1 kW generator can power a 600W electric drill.

Loads such as submersible pumps and air compressors (Driven by induction motor, Initially loaded by water or compressed air at

starting .)

Large power is required to start such load. Therefore, the generator has to supply 3 to 5 times the wattage for starting.

Example : A 1 kW generator is only able to drive a home use pump (up to about 250W).

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Appliance

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Incandescent lamp,hot plate

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Fluorescent lamp,mercury lamp

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Electric tool

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Pump,compressor

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Applicable wattage

60Hz up to 1 ooow up to about 600W up to about 600W up to about 250W

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NOTE :

1. Appliances equipped with electric motors.

They need large starting current as mentioned above. However after starting, the appliance requires only 1.2 to 2 times the wattage to continue running.Therefore, the generator has reserve power for another appliance.

2. Some appliances will indicate output work instead of (input) wattage.

Example : 40W fluorescent lamp means 40W of the light beam is emitted from the lamp.

In such case, efficiency should be considered between the (input) wattage and output work,

Efficiency

0.6 to 0 . 8 . . . . motor

0.7 to 0.8. . . . fluorescent lamp

The (input) wattage determined by the efficiency subjects to the same as above.

3. Voltage drop in long extension wires

When a long wire is used to connect an appliance with the generator, a certain amount of voltage drop occurs in the wire which lessens effective voltage to the appliance.

The table below shows the values for a 1 OOm wire

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Sectional Allowable Gauge No./ area

1 current wire element

A

1

No.lmm

1

Resistance

Ohm11 OOm mm2

30l0.18 2.477

3.5

5.5 35

5OlO. 18

3710.26

4510.32

7010.32

1.486

0.952

0.51 7

0.332

1A

2.5V

Voltage drop per 100 m

3A

8V

5A

12.5V

1.5V

1

.ov

5 v

3 v

1.5v

7.5v

5.0V

2.5V

- 2 v

12V 15V 18V

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11. SPECIFICATIONS

1

DESCRIPTION

1

Engine Model

Displacement cc l c u i n

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G1200R

EY15D (Wl -1 45)

143 I 8.73

60 Frequency HZ

Rated Output Watts

AC Continuous Dutv r

OutputMax. Watts AC

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Engine Speed RPM

Voltage V

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Output DC

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Starting System

Fuel Tank Capacity : Liters

US Gal.

Continuous Operation

Hours Per Tank

Ignition

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1000

1200

3600

120

12 Volts

8.3Amps

Recoil

3.5

0.9

3.5

Transistorized

Automatic Voltage Regulator Yes

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DCBreaker

Carburator

AC Receptacle Unit I Volt

(Amp)

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Yes

Yes

Float

2 I 125V (20A)

G.F.C.I.

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Spark Plus

Oil

Capacity

Liters

Ounces

Low Oil Level

Shutdown System

Spark Plug Wrench with Driver

L

Dimension W mm

H (inches)

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Weight k g

W s )

Specifications are subject to change without notice.

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NGK BR6HS

0.6

21

.o

Yes

1

486 (19.1)

288 (1 1.3)

410 (16.1)

27.5 (60.6)

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12.

WIRING DIAGRAM

(7

3 a

Y

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2

m

=’

0

0 z t z

P

I

--El---

/!

0

IT

0

L L

=!

0 w z\

3

0

0

IT

IT

22

E

W

\ $

3

0

0 a m z

W n z

0

0

MAKITA LIMITED ONE YEAR WARRANTY

Warranty Policy

Every Makita tool is thoroughly ins ected and tested before leaving the fac- tory. It is warranted t o be free of d e g c t s from workmanship and materials for the period of ONE YEAR from t h e date of original purchase. Should any trou- ble develop during this one-year period, return t h e COMPLETE tool, freight prepaid, t o one of Makita’s Factory or Authorized Service Centers. If inspec- tion shows the trouble is caused by defective workmanship or material, Makita will repair (or at our option, replace) without charge.

This Warranty does not apply where:

0 repairs have been made or attempted by others;

0 there is evidence of normal wear and tear;

The tool has been abused, misused or improperly maintained;

0 alterations have been made t o the tool.

Defects are due t o the use of parts, accessories or attachments which are not

Makita genuine products, specifically recommended for use with this tool.

Damage may be caused in transit. (This must be the responsibility of the carrier.) Claims arise from regulations such as for noise levels, exhaust gas emissions, etc. This product has been operated for racing purposes or other competitive activities. This product has been employed for powering equip- ment that is operated on, in or near water or explosive atmospheres.

The following parts are expendable (not durable), so warranty does not apply:

Expendable parts including, but not limited to:

Spark plugs, packings, gaskets, rubber materials, washers, nuts, V-belt, engine oil, grease, paper elements and brushes.

IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCI-

DENTAL OR CONSEQUENTIAL DAMAGES FROM THE SALE O R USE

O F THE PRODUCT. THIS DISCLAIMER APPLIES BOTH DURING AND

AFTER THE TERM O F THIS WARRANTY.

MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES,

IUNCLUDING IMPLIED WARRANTIES O F “MERCHANTABILITY” AND

FITNESS FOR A SPECIFIC PURPOSE,” AFTER THE ONE-YEAR TERM

OF THIS WARRANTY.

This Warranty gives you specific legal rights, and you may also have other rights which vary from state t o state. Some states do not allow the exclusion of limitation of incidental or consequential damages, so the above limitation or exclusion may not apply t o you. Some states do not allow limitation o n how long an implied warranty lasts, so the above limitation may not apply t o you.

Makita Corporation

3-1 8-8, Sumiyoshi-cho

Anjo, Aichi 446 Japan

PRINTED IN JAPAN