MAKITA Generator G12000R SERVICE MANUAL Makita Corporation
CONTENTS Section Title Page 1. SPECIFICATIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1 2. PERFORMANCE CURVES · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 3. GENERAL DESCRIPTION OF GENERATOR · · · · · · · · · · · · · · · · · · · · · · · · · 3 4.
1. SPECIFICATIONS G12000R Model Brush, Self-exciting, 2-pole, Single phase Type Alternator Rated frequency 60Hz 120V / 240V Rated voltage Maximum output 12000VA Rated output 9500V A Power factor 1.0 Engine Voltage regulator A.V.R type Model EH65D Type V-Twin cylinder, Air-cooled, 4-stroke, Overhead valve engine Displacement 653 cm3 Maximum output Fuel 22 HP/ 3600 rpm Unleaded automobile gasoline (RON87 or higher) Oil capacity 1.
2.
3.
CONTROL PANEL (G12000R) OIL PURESSURE WARNING LAMP VOLTMETER NO-FUSE BREAKER PILOT LAMP HOUR METER KEY SWITCH 110 0 120 220 240 IDLE CONTROL SWITCH EARTH (GROUND) TERMINAL CONNECTOR FOR REMOTE CONTROL − 4− − AC RECEPTACLE
SERIAL NUMBER Serial number is stamped on the label stuck on the end cover. NOTE : Always specify serial number when inquiring about the generator or ordering spare parts in order to get correct parts and accurate service.
4. CONSTRUCTION AND FUNCTION 4-1 CONSTRUCTION BRUSH HOLDER STATOR COMPLETE STATOR BOLT REAR COVER ROTOR COMPLETE FRONT COVER MOUNT RUBBER BALL BEARING SLIP RING 4-2 FUNCTION 4-2-1 STATOR The stator consists of a laminated silicon steel sheet core, a main coil which is wound in the core slots.
4-2-2 ROTOR The rotor consists of a laminated silicon steel sheet core and a field coil which is wound over the core. DC current in the field coil magnetizes the steel sheet core. Slip rings are provided on the rotor shaft to receive DC exciting current from A VR (G12000R) 4-2-3 BRUSH / BRUSH HOLDER An exciting current is supplied from the A.V.R to the rotor. The brushes are made of carbon and the brush-holder of plastic.
4-2-5 A.V.R (AUTOMATIC VOLTAGE REGULATOR) (G1200R only) The automatic voltage regulator employs an electronic circuit to automatically regulate voltage. 4-2-6 ECU (ELECTRONIC CONTROL UNIT) ECU controls the start/stop of an engine enabling the fuel cut while stop. It also automatically stops the engine if an abnormal oil pressure occurs.
Function Description of Operation When the key switch or the remote control switch is turned to "START", the fuel cut-off valve of the carburetor opens. When the key switch or the remote control switch is turned to "STOP", the fuel cut-off valve closes. If the starter motor is locked by any reason, the starter motor is shut off automatically after 3 seconds. Fail-safe function When the engine dose not start (engine speed does not reach 1,050 r/min), the starter motor is stopped after 21 seconds.
4-2-8 OIL PRESSURE SWITCH The oil pressure switch sends a signal to ECU to stop the engine when the engine oil pressure drops to 1.0 kg/cm2 4-2-9 RELIEF VALVE The relief valve begins to open when the engine's oil pressure increases above 3.0 kg/cm2 OIL FILTER CAMSHAFT OIL PRESSURE SWITCH CRANKSHAFT OIL PUMP RELIEF VALVE OIL PUMP FILTER 4-2-10 AC SWITCH (NO-FUSE BREAKER) The AC switch (no-fuse breaker) protects the generator from getting damage by overloading or short circuit in the appliance.
4-2-11 AC Receptacle AC receptacles are used for taking AC output power from the generator. A total of 4 kinds of receptacle, each varying in rated voltage and current from another, are used. As many AC plugs as the receptacles, each matching the corresponding receptacle, are provided. The rated current for each receptacle is shown as follows; CAUTION Be careful not to use the receptacles beyond the specified amperage limits to prevent burning.
■ ■ Check the amperage of the receptacles used referring to TABLE 1, and be sure not to take a current exceeding the specified amperage. Be sure that the total wattage of all appliances dose not exceed the rated output of the generator.
GFCI RECEPTACLE After starting the engine, check the GFCI for proper functioning by the following test procedure. ■ Push blue TEST button, The red RESET button will pop out exposing the word TRIP. Power is now off at the outlets protected by the GFCI, indicating that the device is functioning properly. ■ If TRIP dose not appear when testing, do not use the generator. Call a qualified electrician. ■ To restore power, push RESET button.
UTILITY HIGH LINE MAIN POWER LINE CONNECTING BOX 240V RECEPTACLE TRANSFER SWITCH Utility high line House circuit breaker Meter box X W Y 120V appliance 120V appliance X W Y 240V appliance Transfer switch X W Y Generator Generator (W) (W) OR (X) (Y) W (Y) (G) Y X (X) (G) 240V 4P- Receptacle − 14− − 240V 4P- Receptacle
(c) Operating the generator. ■ Turn the house AC breaker off before starting the generator. ■ Start the generator and warm it up. ■ Turn the house AC breaker on. CAUTION Do not start the generator with electrical appliance (s) connected and with their switches on. Otherwise the appliance (s) may be damaged by the surge voltage at starting.
4-3 DESCRIPTION of GENERATOR OPERATION 4-3-1 PRIMARY EXCITING ACTION (G12000R) AVR When the generator is started, the permanent magnet on the engine rotates to generator a voltage in the exciting coil. This voltage is regulated by a diode in the AVR to feed a current to the generator field coil. (FC). (See Fig. 4-1) The rotor is turned an electromagnet by that current and rotates so that voltage are generated in the stator coils (main coil and sub coil).
5. SAFETY PRECAUTIONS 1. Use extreme caution near fuel. A constant danger of explosion or fire exists. Do not fill the fuel tank while the engine is running. Do not smoke or use open flame near the fuel tank. Be careful not to spill fuel when refueling. If spilt, wipe it and let dry before starting the engine. 2. Do not place inflammable materials near the generator. Be careful not to put fuel, matches, gunpowder, oily cloth, straw, and any other inflammables near the generator. 3.
6. RANGE OF APPLICATIONS Generally, the power rating of an electrical appliance indicates the amount of work that can be done by it. The electric power required for operating an electrical appliance is not always equal to the output wattage of the appliance. The electrical appliances generally have a label showing their rated voltage, frequency, and power consumption(input wattage). The power consumption of an electrical appliance is the power necessary for using it.
NOTE 2 : Motor-driven appliances mentioned in lets (3) and (4) vary in their required motor starting power depending on the kind of motor and start-up load. If it is difficult to determine the optimum generator capacity, select a generator with a larger capacity. (5) Appliances without any indication as to power consumption Some appliances have no indication as to power consumption; but instead the work load (output) is indicated.
NOTES : Wiring between generator and electrical appliances 1. Allowable current of cable Use a cable with an allowable current that is higher than the rated input current of the load (electrical appliance). If the input current is higher than the allowable current of the cable used, the cable will become excessively heated and deteriorate the insulation, possibly burning it out. Table 7-2 shows cables and their allowable currents for your reference. 2.
7. MEASURING PROCEDURES 7-1 MEASURING INSTRUMENTS (1) VOLTMETER AC voltmeter is necessary. The approximate AC voltage ranges of the voltmeters to be used for various types of generators are as follows : 0 to 150 V : Type with an output voltage of 110 or 120 V 0 to 300 V : Type with an output voltage of 220, 230 or 240 V 0 to 150 V, 0 to 330 V : Dual voltage type FOR AC (2) AMMETER AC ammeter is necessary.
(4) CIRCUIT TESTER Used for measuring resistance, etc. (5) MEAGER TESTER Used for measuring generator insulation resistance. Select one with testing voltage range of 500V. 7-2 AC OUTPUT MEASURING SWITCH LOAD A ~ TO AC RECEPTACLE F V ~ Use a circuit above for measuring AC output. A hot plate or lamp with a power factor of 1.0 may be used as a load. Adjust the load and rpm. and check that the voltage range is as specified in the following table at the rated amperage and rated rpm.
Model G12000R Rated voltage 120 V 208 V 240 V 112V-128V -------------- 224V-256V 7-3 MEASURING INSULATION RESISTANCE Use a megger tester to check the insulation resistance. Connect a megger tester to one of receptacle output terminals and the ground terminal, then measure the insulation resistance. An insulation resistance of 1MΩ or more is normal. If it is less than 1MΩ, disassemble the generator and measure the insulation resistance of the stator, rotor and control panel individually.
• ROT OR Measure the resistance between the slip ring and the core. • CONTROL PANEL Measure the insulation resistance between the live parts and the grounded parts. Any part where the insulation resistance is less than 1M has faulty insulation, and may cause electric leakage and electric shock. Replace the faulty part.
8. CHECKING FUNCTIONAL MEMBERS 8-1 PILOT LAMP and VOLTMETER Check the pilot lamp and the voltmeter if it is turned on by applying specific voltage. Pilot lamp and voltmeter cannot be checked with circuit tester because its resistance is too large. 8-2 AC RECEPTACLES Using a circuit tester, check continuity between the two terminals at the rear of the AC receptacles while the receptacle is mounted on the control panel.
8-3 AC SWITCH (NO-FUSE BREAKER) Check continuity between each of 2 terminals at the back side of AC switch (no-fuse breaker) while it is mounted on the control panel. Normally, there is continuity between each of the 2 terminals when the breaker is ON, while no continuity when the breaker is OFF. G12000R 8-4 STATOR Disengage connectors on the wires from stator and check the resistance between wires with a circuit tester, referring to the following specification table.
8-5 ROTOR ASSEMBLY 1) Field coil Remove the brush holder and measure resistance between the slip rings. Rotor (Slip ring) G12000R Resistance 4.11Ω NOTE : If the circuit tester is not sufficiently accurate, it may not show the values given and may give erroneous readings. Erroneous reading will also occur when there is a wide variation of resistance among coil windings or when measurement is performed at ambient temperatures different from from 20℃(68 ° F).
8-7 BRUSH The brushes must be smooth where they contact the slip rings. If not, polish smooth the brushes with sandpaper. A brush that is not smooth produces arcs between the brush and slip ring leading to possible damage. Usable brush lengths are from 5 mm to 15 mm (0.2 " to 0.6"). A brush shorter than 5 mm must be replaced because decreased contact pressure between the brush and slip ring lowers generator efficiency and output voltage. 8-8 A.V.
* Checking table for analogue circuit tester.
8-10 IDLE CONTROL UNIT (G12000R only) Check the resistance between five terminals of IDLE CONTROL UNIT with circuit tester. 1 5 2 4 3 Terminal number of the IDLE CONTROL UNIT Circuit tester (with battery power source 1.5 V) Apply red 〇 + needle of the circuit breaker Apply black 〇 - needle of the circuit breaker 1 2 3 1 ------- ∞ 2 ∞ ------- ∞ ------- 65 3 65 ∞ 4 65 ∞ 65 5 6.5 ∞ 6.5 4 65 ∞ 65 ------6.
9. DISASSEMBLY AND ASSEMBLY 9-1 PREPARATION and PRECAUTIONS 1) Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembled correctly. Tag the disassembled part with the necessary information to facilitate easier and smoother reassemble. 2) For more convenience, divide the parts into several groups and store them in boxes.
(7) Remove the stator. (See Fig. 9-3) NOTE : The stator is heavy. Be careful do not hit the coil of the stator to the rotor. Fig. 9-3 (8) Loosen the through bolt of the rotor. (9) Remove the rotor with the soft hammer. (See Fig. 9-4) ROTOR THROUGH BOLT NOTE : Temporarily tighten the through bolt of the rotor when hit the rotor. (See Fig. 9-4) (10) Remove the front cover. SOFT HAMMER Fig.
(1) Generator assembly FRONT COVER BOLT 22.5-24.5Nm 230-250Kg-cm STATOR ROTOR BEARING THROUGH BOLT REAR COVER 11.8-13.7Nm 120-140Kg-cm BRUSH HOLDER BUSHING BRUSH COVER COVER BOLT GENERATOR BASE FLANGE NUT 11.8-13.7Nm 120-140Kg-cm 11.8-13.
(2) Control Box (G12000R) PLATE CONTROL BOX GROMMET WIRE IDLE CONTROL UNIT A.V.R.
(3) Fuel Tank FUEL TANK CAP FUEL GAUGE FILTER FUEL FILTER FRANGE BOLT (M6 x 14 mm) PACKING FUEL TANK CUP HOSE CLAMP DETAIL A A RUBBER PIPE (120 mm) FUEL STRAINER RUBBER WASHER PURSE LOCK FLANGE BOLT (M6 x 14 mm) FUEL PUMP HOSE CLAMP RUBBER PIPE (630 mm) − 35− −
9-4 GENERATOR ASSEMBLING PROCEDURES 9-4-1 FRONT COVER FRONT COVER Attach the front cover to the engine main bearing cover. Match the faucet joint and tighten the bolts. WASHER Tightening torque 230-250 kg cm SPRING WASHER 22.5-24.5 N m 16.6-19.5 ft lbs BOLT Fig. 9-5 9-4-2 ROTOR ROTOR (1) Wipe off oil, grease and dust from the tapered portion of engine shaft and matching tapered hole of rotor shaft. (2) Mount the rotor to the engine shaft. Tighten the through bolt.
9-4-3 STATOR (1) Put the stator in the rear cover setting the four grooves on the side of stator with thread holes of the rear cover. Tighten the four bolts tentatively to check if the grooves and thread holes are aligned correctly. (See Fig.9-8) STATOR STATOR COVER (2) Remove the four bolts. Fig. 9-7 Fig.
9-5 REAR COVER (1) Put the rear cover with stator and stator cover over the rotor. Pull wires out from the rear cover. NOTE : Be careful not to give cuts to wires when pulling them out from the rear cover. Attach the bushing over the lead wire drawn out from the rear cover. Press the smaller end of the bushing into the window of the rear cover. Fig. 9-9 (2) Tap on the rear cover evenly with a plastic hammer to press the rotor bearing into the rear cover.
Attach the connectors to the brush holders. Connector the green wire to the stator end and the brown wire to the bearing end. Install the brush cover. (5) Tighten the nuts over the mount rubber bolts to fix. Tightening torque 120 -140 kg cm Fig. 9-12 11.8 -13.7 N m 8.7-10.1 ft lbs NOTE : When tightening the nuts, slightly lift the alternator assembly so that the weight is not applied to the mount rubbers. (6) Fasten the earth cable to the unpainted bolt hole on the frame. EARTH CABLE Fig.
10. TROUBLESHOOTING 10-1 No AC output * Checking the exciting coil for resistance. (G12000R) (Refer to 8-6.) If insulation is NG, replace exciting coil with new one. * Checking the brush and slip ring of rotor for resistance. (Refer to 8-5 and 8-7.) If insulation is NG, replace brush and slip ring with new one. * Check stator for winding resistance between terminals. (Refer to 8-4.) If stator is faulty, replace with new one. * Checking stator for insulation resistance. (Refer to 7-3.
10-4 Engine dose not run. Symptom 1. Electric starter dose not operate 2. Warning lamp turns on and off when engine is stopped 3. Engine is automatically stopped but the warning lamp dose not light up Possible causes Remedy 1) The key switch (or remote switch) is turned to "START" within 2 seconds the engine has been stopped. Wait for more than 2 seconds and then turn the key switch to "START" position. 2) The remote controller is connected.
11. WIRING DIAGRAM (G12000R) CONTROL BOX Auto choke (Bimetal) Fuel cut Ignition coil R LGrn R Blk/W Blk R/W Blk/W Blk (AC output) Idle solenoid W W Blk Blk 4 5 6 Electronic control unit 2 LBlu 3 4 Idle control unit 13 12 11 10 9 8 7 Org Y LBlu Org R R Electric starter W Oil pressure warning lamp (Red) W W W 1 2 3 Idle control switch Org Y Y (AVR) 1 5 W W Charge coil Exciting coil W Grn Gry Grn/Y Brn Org Grn/Y Org Grn Gry Grn/Y Grn/Y LBlu Magnetic switch -M +M B L.
Makita Corporation
