Makita Portable Generator EG301A User Manual

EG series  
EG301A  
EG381A, EG381AE  
EG511A, EG511AE  
EG711A, EG711AE  
EG781A, EG781AE  
3ZZ9990516  
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(California Proposition 65)  
WARNING:  
The engine exhaust from this product contains  
chemicals known to the State of California to  
cause cancer, birth defects or other reproductive  
harm.  
(California only)  
AIR INDEX  
To show compliance with California emission regulations, a hangtag has been provided  
displaying the Air Index level and durability period of this engine.  
The Air Index level defines how clean an engine’s exhaust is over a period of time. A bar  
graph scaled from “0” (most clean) to “10” (least clean) is used to show an engine’s Air Index  
level. A lower Air Index level represents cleaner exhaust from an engine.  
The period of time (in hours) that the Air Index level is measured is known as the durability  
period. Depending on the size of the engine, a selection of time periods can be used to  
measure the Air Index level (see below).  
Descriptive Term Applicable to Emissions Durability Period  
Moderate  
-
-
-
50 hours (engine from 0 to 80 cc)  
125 hours (engine greater than 80 cc)  
Intermediate  
Extended  
125 hours (engine from 0 to 80 cc)  
250 hours (engine greater than 80 cc)  
300 hours (engine from 0 to 80 cc)  
500 hours (engine greater than 80 cc)  
1000 hours (225 cc and greater)  
Notice : This hangtag must remain on this engine or piece of equipment, and only be  
removed by the ultimate purchaser before operation.  
Notice : FEDERAL EMISSION COMPONENT DEFECT WARRANTY and CALIFORNIA EMISSION CONTROL  
WARRANTY are applicable to only those engines/ generators complied with EPA (Environmental  
Protection Agency) and CARB (California Air Resources Board) emission regulations in the U.S.A.  
Notice : To the engines/generators exported to and used in the countries other than the U.S.A., warranty service  
shall be performed by the distributor in each country in accordance with the standard engine/generator  
warranty policy as applicable.  
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FOREWORD  
Thank you for purchasing a Makita generator.  
This manual covers operation and maintenance of the Makita generators.  
All information in this publication is based on the latest production  
information available at the time of approval for printing.  
Pay special attention to statements preceded by the following words:  
DANGER  
Indicates a possibility of death or serious injury if instructions are not  
followed.  
WARNING  
Indicates a strong possibility of severe personal injury, loss of life and  
equipment damage if instructions are not followed.  
CAUTION]  
Indicates a possibility of personal injury or equipment damage if instructions  
are not followed.  
NOTE:  
Gives helpful information.  
If a problem should arise, or if you have any questions about the generator,  
consult an authorized dealer or service shop  
WARNING  
The generator is designed to give safe and dependable service if  
operated according to instructions.  
Do not operate the generator before you have read and  
understood the instructions. Failure to do so could result in death,  
personal injury or equipment damage.  
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CONTENTS  
1. SAFETY PRECAUTIONS ・・・・・・・・・・・・・・・・ 1  
2. SPECIFICATIONS・・・・・・・・・・・・・・・・・・・ 3  
3. COMPONENTS ・・・・・・・・・・・・・・・・・・・・ 4  
4. PRE-OPERATION CHECKS・・・・・・・・・・・・・・・ 7  
5. OPERATING PROCEDURES ・・・・・・・・・・・・・・11  
6. WATTAGE INFORMATION ・・・・・・・・・・・・・・・21  
7. SPARK ARRESTER ・・・・・・・・・・・・・・・・・・23  
8. MAINTENANCE SCHEDULE ・・・・・・・・・・・・・・24  
9. "HOW-TO" MAINTENANCE・・・・・・・・・・・・・・・26  
10. PREPARATION FOR STORAGE ・・・・・・・・・・・・・30  
11. TROUBLESHOOTING ・・・・・・・・・・・・・・・・・31  
12. WIRING DIAGRAM ・・・・・・・・・・・・・・・・・・32  
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1. SAFETY PRECAUTIONS  
Please make sure you review each precaution carefully.  
WARNING  
Do not operate the generator near gasoline or gaseous fuel because of the  
potential danger of explosion or fire.  
Do not fill the fuel tank with fuel while the engine is running. Do not smoke or  
use open flame near the fuel tank. Be careful not to spill fuel during refueling.  
If fuel is spilt, wipe it off and let dry before starting the engine.  
WARNING  
Do not place in flammables near the generator.  
Be careful not to place fuel, matches, gunpowder, oily cloths, straw, trash, or any other in flammables  
near the generator.  
WARNING  
Do not operate the generator inside a room, cave, tunnel, or other  
insufficiently ventilated area.  
Always operate it in a well-ventilated area, otherwise the engine may  
1m  
become overheated, and the poisonous carbon monoxide gas, an  
odorless, colorless, poison gas, contained in the exhaust gas will  
endanger human lives.  
1m  
Operate generator only outdoors and far from open windows, doors,  
ventilation intakes and other openings.  
Keep the generator at least 1 meter (3 feet) away , including overhead,  
from any structure or building use.  
WARNING  
Do not enclose the generator nor cover it with a box.  
The generator has a built-in forced air cooling system, and may become overheated if it is enclosed.  
If generator has been covered to protect it from the weather during non use, be sure to remove it and  
keep it well away from the area during generator use.  
WARNING  
Operate the generator on a level surface.  
It is not necessary to prepare a special foundation for the generator.  
However, the generator will vibrate on an irregular surface, so choose a level place without surface  
irregularities.  
If the generator is tilted or moved during operation, fuel may spill and / or the generator may tip over,  
causing a hazardous situation.  
Proper lubrication cannot be expected if the generator is operated on a steep incline or slope. In such  
a case, piston seizure may occur even if the oil is above the upper level.  
WARNING  
Pay attention to the wiring or extension cords from the generator to the connected device.  
If the wire is under the generator or in contact with a vibrating part, it may break and  
possibly cause a fire, generator burnout, or electric shock hazard.  
Replace damaged or worn cords immediately.  
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WARNING  
Do not operate in rain, in wet or damp conditions, or with wet hands.  
The operator may suffer severe electric shock if the generator is wet due to rain or snow.  
WARNING  
If wet, wipe and dry it well before starting. Do not pour water directly over the generator, nor wash it  
with water.  
WARNING  
Be extremely careful that all necessary electrical grounding procedures are followed during each and  
every use. Failure to do so can be fatal.  
WARNING  
Do not contact the generator to a commercial power line. Connection to a commercial  
power line may short circuit the generator and ruin it or cause electric shock hazard.  
Use the transfer switch for connecting to domestic circuit.  
WARNING  
No smoking while handling the battery. The battery emits flammable hydrogen gas,  
which can explode if exposed to electric arcing or open flame.  
Keep the area well-ventilated and keep open flames/sparks away when handling the battery.  
WARNING  
Engine becomes extremely hot during and for some time after operation.  
Keep combustible materials well away from generator area.  
Be very careful not to touch any parts of the hot engine especially the muffler area  
or serious burns may result.  
WARNING  
Keep children and all bystanders at a safe distance from work areas.  
WARNING  
It is absolutely essential that you know the safe and proper use of the power tool or appliance that  
you intend to use. All operators must read, understand and follow the tool/appliance owners manual.  
Tool and appliance applications and limitations must be understood. Follow all directions given on  
labels and warnings. Keep all instruction manuals and literature in a safe place for future reference.  
WARNING  
Use only "LISTED" extension cords.  
When a tool or appliance is used outdoors, use only extension cords marked "For Outdoor Use".  
Extension cords, when not in use should be stored in a dry and well ventilated area.  
WARNING  
Always switch off generator's AC circuit breaker and disconnect tools or appliances when not in use,  
before servicing, adjusting, or installing accessories and attachments.  
CAUTION  
Make sure the engine is stopped before starting any maintenance, servicing or repair.  
Make sure maintenance and repair of the generator set are performed by properly trained personnel only.  
2-  
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2. SPECIFICATIONS  
EG381A  
EG511A  
EG711A  
EG781A  
EG301A  
MODEL  
EG381AE EG511AE EG711AE EG781AE  
Brush, self-exciting, 2-poles, single phase  
Type  
Voltage regulating system  
AVR type  
AC Output  
Rated voltage-Frequency  
V-Hz  
A
120-60  
20  
120/240-60  
24.2 / 12.1 35 / 17.5 41.7 / 20.8  
50 / 25  
6000  
Rated current  
2400  
2900  
4200  
1.0  
5000  
Rated output  
VA (W)  
Rated power factor  
Safety device type  
Fuse-less circuit breaker  
DC Output  
Rated voltage  
V
A
12  
8.3  
Rated current  
Safety device type  
Model  
Fuse-less circuit breaker  
EX17D  
EX21D  
EX30D  
EX35D  
EX40D  
Type  
ROBIN, Air-cooled, 4-stroke, OHC, Gasoline Engine  
169  
287  
404  
Displacement  
Fuel  
mL  
211  
Automotive Unleaded Gasoline  
17.8  
22.0  
(27.5)*1  
12.8  
Fuel tank capacity  
L
L
(16.6)*1  
(21.5)*1  
1.0  
1.2  
Engine oil capacity  
Spark plug  
0.6  
BR-6HS (NGK)  
Recoil  
starter  
Starting system  
Direction of rotation  
Length  
Electric starter / Recoil  
Counter - clockwise  
620  
675  
725  
(975)*2  
600  
mm  
(870)*2  
(925)*2  
420  
500  
450  
510  
570  
530  
Width  
mm  
mm  
500  
580  
Height  
52  
69  
86  
89  
(99)*3  
47  
Dry weight  
kg  
kg  
(58)*3  
(79)*3  
(96)*3  
Gross weight  
Weight according to EPTA procedure 01/2003  
62(65)*1  
83(86)*1 104(108)*1 107(111)*1  
57(60)*1  
(68(71))*3 (93(96))*3 (114(118))*3 (117(121))*3  
Specifications are subject to change without notice.  
*1: ( ) shows the filled amount up to the "LEVEL" position.  
*2: ( ) shows dimensions with Battery frame.  
*3: ( ) shows weight with Electric starter.  
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3. COMPONENTS  
EG301A, EG381A, EG381AE, EG511A, EG511AE  
Engine switch  
Fuel tank  
Control panel  
Fuel strainer  
(
)
Fuel valve  
Recoil starter  
handle  
Recoil starter  
Oil gauge (oil filler)  
Oil drain plug  
Tank cap  
Fuel gauge  
Spark plug cap  
Choke lever  
Air cleaner  
Muffler cover  
Exhaust outlet  
4-  
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EG711A, EG711AE, EG781A, EG781AE  
Tank cap  
Engine switch  
Control panel  
Recoil starter  
handle  
Oil gauge (oil filler)  
Oil drain plug  
Recoil starter  
Fuel gauge  
Fuel tank  
Choke lever  
Spark plug cap  
Air cleaner  
Muffler  
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CONTROL PANEL  
EG301A  
Pilot lamp  
AC circuit  
breaker  
AC receptacle 20A  
Engine switch  
DC circuit  
breaker  
(
)
Earth ground  
DC receptacle  
terminal  
EG381A, EG381AE  
AC receptacle 30A  
Pilot lamp  
AC circuit  
breaker  
AC receptacle 20A  
[Electric starter model]  
Key switch  
Idle Control  
Switch  
Full power  
switch  
Engine switch  
DC circuit  
breaker  
ï
(
)
AC circuit  
breaker  
Earth ground  
DC receptacle  
terminal  
EG511A, EG511AE  
EG711A, EG711AE  
EG781A, EG781AE  
AC receptacle 30A  
AC receptacle 20A  
Pilot lamp  
AC receptacle 30A  
[Electric starter model]  
Key switch  
AC circuit  
breaker  
Engine switch  
DC circuit  
breaker  
AC circuit  
breaker  
Full power  
switch  
DC receptacle  
(
)
Earth ground terminal  
6-  
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4. PRE-OPERATION CHECKS  
CHECK ENGINE OIL  
Before checking or refilling oil, be sure  
Oil filler cap  
(Oil gauge)  
generator is located on stable and level  
surface with engine stopped.  
Remove oil filler cap and check the  
engine oil level.  
Upper level  
Lower level  
If oil level is below the lower level line,  
refill with suitable oil (see table) to  
upper level line. Do not screw in the  
oil filler cap when checking oil level.  
Change oil if contaminated.  
(See "How-To" Maintenance.)  
Oil capacity (Upper level) : L (U.S. gal)  
EG301A . . . . . . . . . . . . . . . 0.6 (0.15)  
EG381A, EG381AE . . . . . . 0.6 (0.15)  
EG511A, EG511AE . . . . . . 1.0 (0.26)  
EG711A, EG711AE . . . . . . 1.2 (0.32)  
EG781A, EG781AE . . . . . . 1.2 (0.32)  
Recommended engine oil:  
Use 4-stroke automotive detergent oil  
of API service class SE or higher grade  
5W  
10W  
20W  
#20  
Single grade  
(SG, SH or SJ is recommended). SAE  
10W-30 or 10W-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.  
#30  
#40  
10W  
-30  
Multigrade  
10W  
-
40  
Ambient  
temperature  
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CHECK ENGINE FUEL.  
WARNING  
Do not refuel while smoking or near open flame or other such  
potential fire hazards. Otherwise fire accident may occur.  
NOTE :  
THIS ENGINE IS CERTIFIED TO OPERATE  
ON AUTOMOTIVE UNLEADED GASOLINE.  
LEVEL  
Check fuel level at fuel level gauge.  
If fuel level is low, refill with  
unleaded automotive gasoline.  
Be sure to use the fuel filter screen  
on the fuel filter neck.  
Fuel tank cap  
EG301A  
Fuel filter screen  
EG711A, EG711AE  
Fuel Amount  
up to "LEVEL" position :  
EG381A, EG381AE EG781A, EG781AE  
EG511A, EG511AE  
(L)  
EG301A . . . . . . . . . . . . . . . . . . 12.8  
EG381A, EG381AE . . . . . . . . . 12.8  
EG511A, EG511AE . . . . . . . . . 17.8  
EG711A, EG711AE . . . . . . . . . 22.0  
EG781A, EG781AE . . . . . . . . . 22.0  
FULL  
E
F
EMPTY  
EMPTY  
FULL  
WARNING  
Make sure you review each warning in order to prevent fire hazard.  
Do not refill tank while engine is running or hot.  
Close fuel valve before refueling with fuel.  
Be careful not to admit dust, dirt, water or other foreign objects Into  
fuel.  
Wipe off spilt fuel thoroughly before starting engine.  
Keep open flames away.  
8-  
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CHECKING COMPONENT PARTS  
Check following items before starting engine:  
Fuel leakage from fuel hose, etc.  
Bolts and nuts for looseness.  
Components for damage or breakage.  
Generator not resting on or against any adjacent wiring.  
CHECK GENERATOR SURROUNDINGS  
WARNING  
Make sure you review each warning in order to prevent fire hazard.  
Keep area clear of in flammables or other hazardous materials.  
Keep generator at least 3 feet (1 meter) away from buildings or other  
structures.  
Only operate generator in a dry, well ventilated area.  
Keep exhaust pipe clear of foreign objects.  
Keep generator away from open flame. No smoking!  
Keep generator on a stable and level surface.  
Do not block generator air vents with paper or other material.  
BATTERY INSTALLATION (Electric Starter Model)  
Recommended Battery  
Type  
Capacity (Ah/5hr) ; 12V-21AH or more  
Size ; Less than 185(L) x 125(W) x 160(H) mm  
; Lead-acid battery  
Setting Plate  
Nut  
Earth Cable(BLACK)  
Bolt Protection Plate  
Bolt  
Battery Frame #1  
Bolt  
Starter Cable(RED)  
Nut  
Setting Bolt  
Bolt  
Battery Frame #2  
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Nut  
Bolt  
Battery Plate  
WARNING  
Death, personal injury and/or property damage may occur unless  
instructions are followed carefully.  
Use battery of recommended capacity.  
Turn the starter switch to the "STOP" position when mounting or  
dismounting battery. When mounting battery, connect the positive (+)  
cable first and then the negative (-) cable to the battery. Be careful not to  
short battery cables. When dismounting battery, disconnect negative (  
-)  
cable first.  
RED CABLE  
: To positive (+) terminal  
: To negative ( ) terminal  
BLACK CABLE  
-
Should the connection be made in incorrect manner, the generator will  
be broken.  
Tighten bolts and nuts on terminals securely so they will not be  
loosened by vibration.  
Disconnect battery cables when charging battery.  
GROUNDING THE  
GENERATOR  
To ground the generator to the earth,  
connect the grounding lug of the  
generator to the grounding spike  
driven into the earth or to the  
conductor which has been already  
grounded to the earth.  
Grounding spike  
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.  
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5. OPERATING PROCEDURES  
STARTING THE GENERATOR  
CAUTION  
Check the oil level before each operations as outlined by the article  
"CHECK ENGINE OIL"  
(a) Turn the Engine switch to the position  
ON  
"ON".  
OFF  
(b) Turn the AC circuit breaker to the  
position "OFF".  
ON  
OFF  
OFF  
(c) Open the fuel valve.  
CLOSE  
CLOSE  
OPEN  
(d) Set choke lever to close if the engine  
Choke lever  
is cold.  
CLOSE  
OPEN  
11-  
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(e) [Recoil starter model]  
Pull the starter handle slowly until  
passing the compression point  
(resistance will be felt), then return  
the handle to its original position  
and pull briskly.  
If the engine fails to start after several  
attempts, repeat above procedures  
with choke lever returned to "OPEN"  
position.  
Do not fully pull out the rope.  
After starting, allow the starter handle  
to return to its original position while  
still holding the handle.  
(f) [Electric starter model]  
STOP  
Insert the key into the key switch and  
turn it clockwise to the "RUN" position  
to start the engine.  
RUN  
RUN  
STOP  
START  
START  
Then turn the key further to the  
"START" position. The engine will be  
started by starting motor.  
CAUTION  
Do not run the starting motor over 5 seconds continuously.  
If the engine fails to start, return the key to the "RUN" position and wait  
about 10 seconds then start again.  
Do not turn the key switch to "START" position when the engine is  
running to prevent damage of starting motor.  
When starting the engine by recoil starter, set the key switch at the "ON"  
position and pull the starter handle.  
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(g) After the engine started, return the  
choke lever gradually to "OPEN"  
position.  
Choke lever  
CLOSE  
OPEN  
(h) Warm up the engine without a load for  
a few minutes.  
13-  
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USING ELECTRIC POWER  
WARNING  
Make sure that the appliance is switched OFF before connecting it to  
the generator.  
Do not move the generator while it is running.  
Be sure to ground the generator if the connected appliance is  
grounded. Failure to ground unit may lead to electrical shock.  
(1) AC APPLICATION  
(a) Make sure the pilot lamp is turned on.  
(b) Turn off the switch (es) of the electrical  
appliance (s) before connecting to the  
generator.  
(c) Insert the plug (s) of the electrical  
appliance(s) into the receptacle.  
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.  
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Style  
Ampere  
Receptacle  
AC plug  
Description  
GFCI (Ground Fault  
Circuit Interrupter)  
Receptacle, duplex  
(REC1)  
NEMA  
5-20R  
NEMA  
5-20P  
up to 20A  
NEMA  
L5-30R  
NEMA  
L5-30P  
Locking Receptacle  
(REC3)  
up to 30A  
up to 30A  
NEMA  
L14-30R  
NEMA  
L14-30P  
Locking Receptacle  
(REC4)  
TABLE 1  
WARNING  
TWIST  
To take power out from the TWIST  
LOCK RECEPTACLE, insert the  
plug into the receptacle, and turn  
it clockwise to the lock position.  
Be sure to ground the generator if  
the connected electrical device Is  
grounded.  
NOTE :  
When the AC circuit breaker turns off during operation, the generator is over  
loaded or the appliance is defective. Stop the generator immediately, check the  
appliance and / or generator for overloading or detect and have repaired as  
necessary by Makita factory or authorized service center.  
CAUTION  
The duplex 120V receptacle is protected by a GFCI (Ground Fault Circuit  
Interrupter). GFCI shuts off the output current from the duplex 120V  
receptacle when a ground fault occurs in the generator or the appliance.  
Please note that other receptacles are not protected by GFCI.  
15-  
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(d) Turn the AC circuit breaker to the  
position "ON".  
ON  
(e) Turn on the switch of the appliance.  
OFF  
ON  
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.  
WARNING  
If the RESET button pops out during operation, stop the generator  
immediately and call a qualified electrician for checking generator and  
the appliances.  
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FULL POWER SWITCH (Except EG301A)  
Select the voltage using the FULL  
POWER SWITCH in accordance with the  
electrical appliance.  
120V  
240V  
Refer to TABLE 2.  
120V  
CAUTION  
Change the FULL POWER SWITCH  
after turning the AC circuit breaker  
to "OFF".  
Switch position  
120V  
Lower Voltage Receptacle  
Activated full rated output  
Activated half of rated output  
TABLE 2  
Higher Voltage Receptacle  
N.A  
120/240V  
Activated full rated output  
(1) CHECKING THE OPERATION  
Overloaded ?  
Please make it sure that the generator is not overload.  
NOTE :  
Most induction loads such as electric motors require three to five times more  
wattage than their ratings during starting.  
(2) STOPPING THE ENGINE  
Turn off the switch of load.  
Switch off generator's AC breaker.  
Disconnect tool or appliance.  
Turn the STOP SWITCH to the position "O" (OFF).  
NOTE :  
Allow the engine about 3 minutes to cool down at no-load before stopping.  
17-  
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(2) DC APPLICATION  
(Only for charging 12 volt battery)  
BLACK  
CABLE  
DC receptacle (Only for charging 12 volt  
battery)  
RED  
CABLE  
-
+
For charging 12 voltage battery, 12V-8.3A  
(100W) of maximum AC power can be  
taken out from the DC receptacle by  
means of the exclusive DC cable.  
DC receptacle  
The exclusive DC cable is come with your  
generator set (included in the package).  
DC Circuit Breaker  
DC circuit breaker is turned off to shut down the DC power, when the DC is over  
the usage range or the battery is defective.  
Check the generator and/or battery for overloading or defect, and turn on the DC  
circuit breaker after no problem and defect are found out.  
Connection of exclusive DC cable :  
Connect positive (red) clip of DC cable to positive (+) terminal on battery.  
Connect negative (black) clip of DC cable to negative (-) terminal on battery.  
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Battery Charging Procedures :  
1) Stop engine.  
2) Remove all connections from battery.  
3) Insert the plug of exclusive DC cable into DC receptacle.  
4) Connect positive (red) clip of DC cable to positive (+) terminal on battery, and  
then connect negative (black) clip of DC cable to negative (-) terminal on  
battery.  
5) Take out all plugs at the battery electrolyte fluid filler ports.  
6) Check the electrolyte fluid level, and refill the distilled water as necessary.  
7) Start engine.  
8) Make sure that the pilot lamp is turned on.  
9) Make sure that the DC circuit breaker is in the ON position.  
10) Battery charging will be started.  
CAUTION  
Do not use both AC and DC output at the same time.  
Install correct positive (red) or negative (black) cable to the correct  
polarity on the battery.  
Connect and disconnect DC cable with engine stopped.  
An explosive hydrogen gas is discharged through vent holes in the  
battery during the charging process.  
Do not allow spark or open flame around the generator or battery during  
the charging process.  
Electrolyte fluid contains sulphuric acid, and so the fluid can burn eyes  
and clothing. Be extremely careful to avoid contact.  
If injured, wash the affected area immediately with large quantities of  
water and consult a doctor for treatment.  
Charging time is varied according to the kind of battery and discharged  
level of battery.  
Measure the specific gravity of electrolyte fluid by means of hydrometer  
every one hour during battery charging.  
Make sure if the DC circuit breaker is not turned off.  
Battery charging is completed when the specific gravity is in the range of  
1.26 to 1.28.  
19-  
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ON  
STOPPING THE GENERATOR  
(a) Turn off the power switch of the  
electric equipment and unplug the cord  
from receptacle of the generator.  
OFF  
OFF  
(b) Turn the AC circuit breaker to the  
"OFF" position.  
ON  
(c) Allow the engine about 3 minutes to  
cool down at no-load before stopping.  
(d)Recoil starter model  
Turn the engine switch to the position  
"OFF".  
OFF  
RUN  
STOP  
RUN  
STOP  
ST  
ART  
Electric starter model]  
Turn the key switch to the STOP  
position.  
START  
(e) Close the fuel valve.  
OIL SENSOR  
CLOSE  
(a) The oil sensor detects the fall in oil  
level in the crankcase and automati-  
cally stops the engine when the oil  
level falls below a predetermined level.  
CLOSE  
(b) When engine has stopped  
automatically, switch off generator's  
AC circuit breaker, and check the oil  
level.  
OPEN  
Refill engine oil to the upper level as  
instructed on page 7 and restart the  
engine.  
Oil sensor  
(c) If the engine does not start by usual  
starting procedures, check the oil level.  
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6. WATTAGE INFORMATION  
Some appliances need a "surge" of energy when starting.  
This means that the amount of electrical power needed to start the appliance may exceed  
the amount needed to maintain its use.  
Electrical appliances and tools normally come with a label indicating voltage, cycles / Hz,  
amperage (amps) and electrical power needed to run the appliance or tool.  
Check with your nearest dealer or service center with questions regarding power surge of  
certain appliances or power tools.  
Electrical loads such as incandescent lamps and hot plates require the same wattage  
to start as is needed to maintain use.  
Loads such as fluorescent lamps require 1.2 to 2 times the indicated wattage during  
start-up.  
Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.  
Electrical motors require a large starting current. Power requirements depend on the  
type of motor and its use. Once enough "surge" is attained to start the motor,  
the appliance will require only 50% to 30% of the wattage to continue running.  
Most electrical tools require 1.2 to 3 times their wattage for running under load during  
use. For example, a 5,000 watt generator can power a 1800 to 4000 watt electrical  
tool.  
Loads such as submersible pumps and air compressors require a very large force to  
start. They need 3 to 5 times the normal running wattage in order to start.  
For example, a 5,000 watt generator would only be able to drive a 1,000 to 1,700 watt  
pump.  
NOTE :  
The following wattage chart is general guide only. Refer to your specific appliance for  
correct wattage.  
To determine the total wattage required to run a particular electrical appliance or tool,  
multiply the voltage figure of the appliance/tool by the amperage (amps) figure of same.  
The voltage and amperage (amps) information can be found on a name plate which is  
normally attached to electrical appliances and tools.  
Applicable Wattage(W)  
Applications  
EG381A  
EG511A  
EG711A  
EG781A  
EG301A  
EG381AE EG511AE EG711AE EG781AE  
Incandescent lamp, Heater  
Fluorescent lamp, Electric tool  
Mercury lamp  
2400  
1300  
950  
2900  
1600  
1150  
700  
4200  
2300  
1700  
1050  
5000  
2750  
2000  
1250  
6000  
3300  
2400  
1500  
Pump, Compressor  
600  
21-  
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VOLTAGE DROP IN ELECTRIC EXTENSION CORDS  
When a long electric extension cord is used to connect an appliance or tool to the  
generator, a certain amount of voltage drop or loss occurs in the extension cord  
which reduces the effective voltage available for the appliance or tool.  
The chart below has been prepared to illustrate the approximate voltage loss when  
an extension cord of 300 feet (approx. 100 meters) is used to connect an  
appliance or tool to the generator.  
Nominal  
cross  
section  
Allowable No.of strands  
Resistance  
A.W.G.  
Current Amp.  
current  
/ strands dia.  
mm2  
0.75  
1.27  
2.0  
No.  
18  
A
No./mm  
30/0.18  
50/0.16  
37/0.26  
45/0.32  
70/0.32  
1A 3A 5A 8A 10A 12A 15A  
Ω/100m  
7
2.477 2.5V 8V 12.5V  
16  
12  
17  
23  
35  
1.486 1.5V 5V 7.5V 12V 15V 18V  
14  
0.952  
0.517  
0.332  
1V 3V 5V 8V 10V 12V 15V  
3.5  
12 to 10  
10 to 8  
1.5V 2.5V 4V 5V 6.5V 7.5V  
1V 2V 2.5V 3.5V 4V 5V  
5.5  
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7. SPARK ARRESTER  
In a dry or wooded area, it is recommendable to use the product with a spark arrester.  
Some areas require the use of a spark arrester. Please check your local laws and  
regulations before operating your product  
.
The spark arrester must be cleaned regularly to keep it functioning as designed.  
A clogged spark arrester :  
Prevents the flow of exhaust gas  
Reduces engine output  
Increases fuel consumption  
Makes starting difficult  
If the engine has been running, the muffler and the spark arrester will be very hot.  
Allow the muffler to cool before cleaning the spark arrester.  
How to remove the spark arrester  
1. Remove the flange bolts from the muffler cover and remove the muffler cover.  
2. Remove the special screw from the spark arrester and remove the spark arrester  
from the muffler.  
EG711A  
EG301A  
EG711AE  
EG381A  
EG781A  
EG381AE  
EG781AE  
EG511A  
EG511AE  
Muffler  
cover  
Spark  
arrester  
screen  
Exhaust  
outlet  
Screw  
Screw  
Muffler  
Spark arrester screen  
Clean the spark arrester screen  
Use a brush to remove carbon deposits from the spark arrester screen.  
Be careful to avoid damaging the screen.  
The spark arrester must be free of breaks and holes. Replace the spark arrester if it  
is damaged.  
Install the spark arrester, and muffler protector in the reverse order of disassembly.  
EG711A  
EG301A  
EG711AE  
EG381A  
Spark arrester screen  
Spark arrester screen  
EG781A  
EG381AE  
EG781AE  
EG511A  
EG511AE  
23-  
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8. MAINTENANCE SCHEDULE  
MAINTENANCE, REPLACEMENT, OR REPAIR OF THE EMISSION CONTROL DEVICES  
AND SYSTEMS MAY BE PERFORMED BY ANY NONROAD ENGINE REPAIR  
ESTABLISHMENT OR INDIVIDUAL.  
DAILY INSPECTION  
Before running the generator, check the following service items:  
Enough gasoline  
Excessive vibration,noise  
Enough clean engine oil  
Loose or broken bolts and nuts  
Leakage of gasoline and engine oil  
Safe surroundings  
Clean air cleaner element  
PERIODIC MAINTENANCE  
Periodic maintenance is vital to safe and efficient operation of your generator.  
Check the table below for periodic maintenance intervals.  
IT IS ALSO NECESSARY FOR THE USER OF THIS GENERATOR TO  
CONDUCT THE MAINTENANCE AND ADJUSTMENTS ON THE EMISSION-  
RELATED PARTS LISTED BELOW TO KEEP THE EMISSION CONTROL  
SYSTEM EFFECTIVE.  
The emission control system consists of the following parts :  
(1) Carburetor and internal  
parts  
(4) Air cleaner elements  
(5) Spark plug  
(8) Exhaust manifold, if  
applicable  
(2) Cold start enrichment  
system, if applicable  
(9) Hoses, belts,  
connectors, and  
assemblies  
(6) Magneto or electronic  
ignition system  
(3) Intake manifold, if  
applicable  
(7) Spark advance/retard  
system, if applicable  
The maintenance schedule indicated in the table is based on the normal generator  
operation. Should the generator be operated in extremely dusty condition or in  
heavier loading condition, the maintenance intervals must be shortened depending  
on the contamination of oil, clogging of filter elements, wear of parts, and so on.  
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Periodic Maintenance Schedule table  
Every  
8 hours  
(Daily)  
Every  
50 hours 200 hours  
(Weekly) (Monthly)  
Every  
Every  
500  
hours  
Every  
1000  
hours  
Maintenance Items  
(Daily)  
Clean generator and check bolt and nuts  
Check and refill engine oil  
(Refill daily up to upper level)  
Change engine oil (*Note1)  
(Initial  
(Every  
20 hours) 100 hours)  
(Every 100 hours)  
Clean spark plug  
Clean air cleaner  
(Every 100 hours)  
Clean spark arrester  
Replace air cleaner element  
Clean fuel filter  
Clean and adjust spark plug and electrodes  
Replace spark plug  
Remove carbon from cylinder head (*Note 2)  
Check and adjust valve clearance (*Note 2)  
Clean and adjust carburetor (*Note 2)  
Check and replace carbon brushes  
Replace fuel lines  
(Yearly)  
Overhaul engine (*Note 2)  
(Daily)  
(Daily)  
(Daily)  
Check AC receptacles  
Check DC termianl  
Check engine switch  
Check rotor  
Check stator  
Replace engine mount  
*Note: 1. Initial oil change should be performed after first twenty (20) hours of operation.  
Thereafter change oil every hundred (100) hours.  
Before changing oil, check for a suitable way to dispose of old oil.  
Do not pour it down into sewage drains, onto garden soil or into open streams. Your  
local zoning or environmental regulations will give you more detailed instructions on  
proper disposal.  
*Note: 2. As to the procedures for these items, please refer to the SERVICE MANUAL or  
consult your nearest Makita factory or authorized service center.  
25-  
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9. "HOW-TO" MAINTENANCE  
ENGINE OIL CHANGE  
Change engine oil every 100 hours.  
(For new engine, change oil after 20  
hours.)  
(a) Drain oil by removing the drain plug  
and the oil filler cap while the engine  
is warm.  
Oil drain plug  
(b) Reinstall the drain plug and fill the engine with oil until it reaches the upper level  
on the oil filler cap.  
Use fresh and high quality lubricating oil to the specified level as directed on page 7.  
If contaminated or deteriorated oil is used or the quantity of the engine oil is not  
sufficient, the engine damage will result and its life will be greatly shortened.  
SERVICING THE AIR CLEANER  
Maintaining an air cleaner in proper condition is very important.  
Dirt induced through improperly installed, improperly serviced or inadequate  
elements damages and wears out engines. Keep the element always clean.  
(a) Remove the bolt of air cleaner cover. (EG711A, EG711AE, EG781A, EG781AE)  
Remove the air cleaner cover and cleaner element.  
(b) Urethane form : Wash urethane form element in kerosene or diesel fuel. Then  
saturate the element in a mixture of 3 parts kerosene or diesel fuel and 1 part  
engine oil.  
Squeeze the element to remove the mixture and install it in the air cleaner.  
NOTE :  
Instead of washing oil (kerosene), it is possible to wash the urethane foam element  
in a solution of mild detergent and warm water.  
Then rinse the element thoroughly in clean water.  
Allow the element to dry thoroughly. Soak the element in clean engine oil and  
squeeze out excess oil.  
EG301A, EG381A, EG381AE  
Element  
EG511A, EG511AE  
EG711A, EG711AE  
EG781A, EG781AE  
Element  
Base  
Bolt  
Element  
Base  
Base  
Air cleaner  
cover  
Air cleaner  
cover  
Air cleaner  
cover  
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CLEANING AND ADJUSTING  
SPARK PLUG  
(a) If the plug is contaminated with carbon,  
remove it using a plug cleaner or wire  
brush.  
(b) Adjust the electrode gap to 0.6 to 0.7  
mm (0.024 to 0.028 in.).  
Gap 0.6 to 0.7 mm  
(
)
0.024 to 0.028 in.  
Spark plug : BR-6HS (NGK)  
CLEANING FUEL STRAINER  
Dirt and water in the fuel are removed by  
the fuel strainer.  
(a) Remove the strainer cup and throw  
away water and dirt.  
(b) Clean the screen and strainer cup  
with gasoline.  
(c) Tightly fasten the cup to main body,  
making sure to avoid fuel leak.  
27-  
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CHECKING CARBON BRUSH  
Brush Maintenance Essentials (Effective Length)  
The brush is the area which touches the slip ring, and its surface must be kept  
smooth.  
If it is not smooth then carbon and other substances will adhere between the brush  
and slip ring.  
This must be buffed with sandpaper or the like because it is hazardous.  
The usable length of the brush is 5~11mm, so if the brush is 5mm long or less  
replace it with a new one.  
This is done because if the length of the  
brush gets any shorter, its contact  
pressure with the slip ring will decrease,  
resulting in a drop in generator efficiency  
and the output voltage.  
Check the brush every 500 hours to  
Length when new  
confirm its length.  
In addition, check the brush length if the  
generator malfunctions, such as when it is  
10~11mm  
not generating power or its voltage is low.  
Effective brush length  
5 mm  
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Brush Maintenance Essentials (Disassembly and Assembly)  
Disassembly  
1. Remove the two flange bolts (M5 x 20),  
then remove the bracket cover.  
Brush  
2. Remove the two flange bolts (M5 x 16),  
then remove the brush.  
Slip ring  
Assembly  
1. While pressing the brush against the  
slip ring, secure it (1.5~2Nm) by  
tightening it with the two flange bolts  
Brush holder  
Flange bolts  
(M5 x 16).  
When doing so, confirm that the brush  
is in the proper position relative to the  
slip ring.  
2. Secure the bracket cover (3~4Nm) by  
tightening it with the two flange bolts  
(M5 x 20).  
Bracket cover  
Flange bolts  
29-  
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10. PREPARATION FOR STORAGE  
The following procedures should be followed prior to storage of your generator for  
periods of 6 months or longer.  
Drain fuel from fuel tank carefully by  
disconnecting the fuel line.  
Gasoline left in the fuel tank will  
eventually deteriorate making engine-  
starting difficult.  
Drain screw  
Remove the carburetor float chamber  
and also drain the carburetor.  
Change engine oil.  
Check for loose bolts and screws,  
tighten them if necessary.  
Clean generator thoroughly with oiled cloth. Spray with preservative if  
available. NEVER USE WATER TO CLEAN GENERATOR !  
Pull starter handle until resistance is felt, leaving handle in that position.  
Store generator in a well ventilated, low humidity area.  
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11. TROUBLESHOOTING  
When generator engine fails to start after several attempts, or if no electricity is  
available at the output socket, check the following chart. If your generator still fails  
to start or generate electricity, contact your nearest Makita factory or authorized  
service center for further information or corrective procedures.  
When Engine Fails to Start :  
Set the choke lever to "CLOSE"  
position.  
Check if choke lever is in its proper  
position.  
Check if fuel valve is open.  
Check fuel level.  
If closed, open fuel valve.  
If empty, refill fuel tank making sure not  
to overfill.  
Check if engine switch is in OFF.  
Turn engine switch to ON.  
Check to make sure generator is not  
connected to an appliance.  
If connected, turn off the power switch  
on the connected appliance and unplug.  
Check spark plug for loose spark plug  
cap.  
If loose, push spark plug cap back into  
place.  
Check spark plug for contamination.  
Remove spark plug and clean electrode.  
When No Electricity Is Generated at Receptacle :  
After making sure that the total wattage  
of the electrical appliance is within  
permissible limits and there are no  
defects in the appliance, turn the AC  
circuit breaker to the "ON" position.  
If breakers continue to actuate, consult  
your nearest servicing dealer.  
Check to make sure AC circuit breaker  
is in the "ON" position.  
Check AC receptacle and DC terminals  
for loose connection.  
Secure connection if necessary.  
Turn off switch on the appliance, and  
disconnect cable from receptacle.  
Reconnect after generator has been  
started properly.  
Check to see if engine starting was  
attempted with appliances already  
connected to generator.  
Low power.  
Carbon brushes are excessively worn  
31-  
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12. WIRING DIAGRAM  
P i l o t l a m p  
O i l s e n s o r u n i t  
D C w i n d i n g  
Y
Y
O i l s e n s o r s w i t c h  
I g n i t i o n c o i l  
B l u  
B r n  
B l u  
B r n  
B l u  
Y
S p a r k p l u g  
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G r n / Y  
b r e a k e r  
A C c i r c u i t  
P i l o t l a m p  
O i l s e n s o r u n i t  
D C w i n d i n g  
Y
Y
O i l s e n s o r s w i t c h  
I g n i t i o n c o i l  
B l u  
B r n  
B l u  
B r n  
B l u  
S p a r k p l u g  
Y
33-  
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G r n / Y  
b r e a k e r  
A C c i r c u i t  
P i l o t l a m p  
C h a r g e c o i l  
M a g n e t i c s w i t c h  
E l e c t r i c s t a r t e r  
O i l s e n s o r u n i t  
D C w i n d i n g  
Y
Y
O i l s e n s o r s w i t c h  
I g n i t i o n c o i l  
B l u  
B r n  
B l u  
B r n  
B l u  
Y
S p a r k p l u g  
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G r n / Y  
b r e a k e r  
b r e a k e r  
A C c i r c u i t  
A C c i r c u i t  
b r e a k e r  
b r e a k e r  
A C c i r c u i t  
A C c i r c u i t  
P i l o t l a m p  
O i l s e n s o r u n i t  
D C w i n d i n g  
B l u  
B l u  
B l u  
O i l s e n s o r s w i t c h  
B l u  
W
I g n i t i o n c o i l  
W
G r n  
G r n  
R
W
S p a r k p l u g  
35-  
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G r n / Y  
b r e a k e r  
A C c i r c u i t  
b r e a k e r  
A C c i r c u i t  
b r e a k e r  
A C c i r c u i t  
b r e a k e r  
A C c i r c u i t  
P i l o t l a m p  
C h a r g e c o i l  
M a g n e t i c s w i t c h  
E l e c t r i c s t a r t e r  
O i l s e n s o r u n i t  
D C w i n d i n g  
B l u  
B l u  
W
O i l s e n s o r s w i t c h  
I g n i t i o n c o i l  
W
G r n  
G r n  
R
W
S p a r k p l u g  
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