EG series
EG301A
EG381A, EG381AE
EG511A, EG511AE
EG711A, EG711AE
EG781A, EG781AE
EG301A
EG381A, EG381AE
EG511A, EG511AE
EG711A, EG711AE
EG781A, EG781AE
séries
3ZZ9990516
EG
EG781AE ce_GU6837 10.1.25 1:36 PM ページ001
(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
-
125 hours (engine from 0 to 80 cc)
250 hours (engine greater than 80 cc)
Extended
-
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.
EG781AE ce_GU6837 10.1.25 1:36 PM ページ002
EG781AE ce_GU6837 10.1.25 1:36 PM ページ01
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.
ENGLISH
FOREWORD
EG781AE ce_GU6837 10.1.25 1:36 PM ページ02
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
EG781AE ce_GU6837 10.1.25 1:36 PM ページ1
1. SAFETY PRECAUTIONS
ENGLISH
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
become overheated, and the poisonous carbon monoxide gas, an
odorless, colorless, poison gas, contained in the exhaust gas will
endanger human lives.
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.
1m
1m
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.
− 1−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ2
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−
EG781AE ce_GU6989 10.2.8 1:48 PM ページ3
MODEL
EG381A
EG381AE
EG301A
EG511A
EG511AE
EG711A
EG711AE
EG781A
EG781AE
Brush, self-exciting, 2-poles, single phase
Type
Voltage regulating system
AVR type
Generator
AC Output
Rated voltage-Frequency
V-Hz
Rated current
A
Rated output
VA (W)
120-60
120/240-60
20
24.2 / 12.1
35 / 17.5
41.7 / 20.8
50 / 25
2400
2900
4200
5000
6000
Rated power factor
1.0
Safety device type
Fuse-less circuit breaker
DC Output
Rated voltage
V
Rated current
A
12
8.3
Safety device type
Fuse-less circuit breaker
Engine
mL
169
EX35D
287
211
Fuel
EX40D
404
Automotive Unleaded Gasoline
Fuel tank capacity
L
Engine oil capacity
L
22.0
(27.5)*1
17.8
(21.5)*1
12.8
(16.6)*1
1.0
0.6
Spark plug
1.2
BR-6HS (NGK)
Recoil
starter
Starting system
Electric starter / Recoil
Counter - clockwise
Direction of rotation
Dimension
EX30D
ROBIN, Air-cooled, 4-stroke, OHC, Gasoline Engine
Type
Displacement
EX21D
EX17D
Model
675
(925)*2
725
(975)*2
Length
mm
600
620
(870)*2
Width
mm
420
450
510
530
Height
mm
500
500
570
580
kg
47
52
(58)*3
69
(79)*3
kg
57(60)*1
62(65)*1
(68(71))*3
Dry weight
Gross weight
Weight according to EPTA procedure 01/2003
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.
− 3−
86
(96)*3
89
(99)*3
83(86)*1 104(108)*1 107(111)*1
(93(96))*3 (114(118))*3 (117(121))*3
ENGLISH
2. SPECIFICATIONS
EG781AE ce_GU6837 10.1.25 1:36 PM ページ4
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
Fuel gauge
Tank cap
Spark plug cap
Choke lever
Air cleaner
Muffler cover
Exhaust outlet
− 4−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ5
Tank cap
ENGLISH
EG711A, EG711AE, EG781A, EG781AE
Engine switch
Control panel
Recoil starter
handle
Oil gauge (oil filler)
Recoil starter
Oil drain plug
Fuel gauge
Fuel tank
Choke lever
Spark plug cap
Air cleaner
Muffler
− 5−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ6
CONTROL PANEL
EG301A
AC circuit
breaker
AC receptacle 20A
Engine switch
Pilot lamp
DC circuit
breaker
Earth (ground)
terminal
EG381A, EG381AE
AC receptacle 30A
AC receptacle 20A
DC receptacle
AC circuit
breaker
[Electric starter model]
Pilot lamp
Idle Control
Switch
Key switch
Full power
switch
Engine switch
DC circuit
breaker
ï
AC circuit
breaker
EG511A, EG511AE
EG711A, EG711AE
EG781A, EG781AE
Earth (ground)
terminal
AC receptacle 30A
DC receptacle
AC receptacle 30A
AC receptacle 20A
Pilot lamp
[Electric starter model]
AC circuit
breaker
Key switch
DC circuit
breaker
Engine switch
AC circuit
breaker
Full power
DC receptacle
switch
Earth (ground) terminal
− 6−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ7
4. PRE-OPERATION CHECKS
Before checking or refilling oil, be sure
generator is located on stable and level
surface with engine stopped.
■
■
■
Remove oil filler cap and check the
engine oil 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.
ENGLISH
CHECK ENGINE OIL
Oil filler cap
(Oil gauge)
Upper level
Lower 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
(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.
5W
10W
Single grade
20W
#20
#30
#40
Multigrade
Ambient
temperature
− 7−
10W-30
10W-40
EG781AE ce_GU6837 10.1.25 1:36 PM ページ8
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
EG381A, EG381AE
EG511A, EG511AE
Fuel Amount
up to "LEVEL" position :
(L)
EG301A . . . . . . . . . . . . . . . . . . 12.8
EG381A, EG381AE . . . . . . . . . 12.8
EG511A, EG511AE . . . . . . . . . 17.8
EG711A, EG711AE . . . . . . . . . 22.0
EG781A, EG781AE . . . . . . . . . 22.0
FULL
Fuel filter screen
EG711A, EG711AE
EG781A, EG781AE
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−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ9
ENGLISH
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
; Lead-acid battery
Capacity (Ah/5hr) ; 12V-21AH or more
Size
; Less than 185(L) x 125(W) x 160(H) mm
Earth Cable(BLACK)
Setting Plate
Nut
Starter Cable(RED)
Bolt
Battery Frame #1
Bolt
Setting Bolt
Bolt
Battery Plate
Battery Frame #2
− 9−
Protection Plate
Bolt
Nut
Nut
Bolt
EG781AE ce_GU6837 10.1.25 1:36 PM ページ10
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
BLACK CABLE
: To negative (-) terminal
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.
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.
− 10−
Grounding spike
EG781AE ce_GU6837 10.1.25 1:36 PM ページ11
5. OPERATING PROCEDURES
ENGLISH
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
is cold.
Choke lever
CLOSE
OPEN
− 11−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ12
(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.
■
■
■
ly
isk
r
ll b
Pu
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]
Insert the key into the key switch and
turn it clockwise to the "RUN" position
to start the engine.
Then turn the key further to the
"START" position. The engine will be
started by starting motor.
STOP
RUN
STOP
RUN
ST
AR
T
START
[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.
− 12−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ13
( g) After the engine started, return the
choke lever gradually to "OPEN"
position.
ENGLISH
Choke lever
CLOSE
OPEN
(h) Warm up the engine without a load for
a few minutes.
− 13−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ14
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.
− 14−
Style
Ampere
Receptacle
AC plug
Description
up to 20A
NEMA
5-20R
NEMA
5-20P
GFCI (Ground Fault
Circuit Interrupter)
Receptacle, duplex
up to 30A
NEMA
L5-30R
NEMA
L5-30P
Locking Receptacle
(REC3)
up to 30A
NEMA
L14-30R
NEMA
L14-30P
Locking Receptacle
(REC4)
(REC1)
TABLE 1
WARNING
■
■
To take power out from the TWIST
LOCK RECEPTACLE, insert the
plug into the receptacle, and turn
it clockwise to the lock position.
TWIST
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−
ENGLISH
EG781AE ce_GU6837 10.1.25 1:36 PM ページ15
EG781AE ce_GU6837 10.1.25 1:36 PM ページ16
(d) Turn the AC circuit breaker to the
position "ON".
ON
(e) Turn on the switch of the appliance.
ON
OFF
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.
− 16−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ17
ENGLISH
FULL POWER SWITCH (Except EG301A)
Select the voltage using the FULL
POWER SWITCH in accordance with the
electrical appliance.
Refer to TABLE 2.
120V
240V
120V
[CAUTION]
Change the FULL POWER SWITCH
after turning the AC circuit breaker
to "OFF".
Switch position
Lower Voltage Receptacle
Higher Voltage Receptacle
120V
Activated full rated output
N.A
120/240V
Activated half of rated output
Activated full rated output
TABLE 2
(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−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ18
(2) DC APPLICATION
(Only for charging 12 volt battery)
DC receptacle (Only for charging 12 volt
battery)
BLACK
CABLE
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.
− 18−
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−
ENGLISH
EG781AE ce_GU6837 10.1.25 1:36 PM ページ19
EG781AE ce_GU6837 10.1.25 1:36 PM ページ20
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
STOP
STOP
[Electric starter model]
Turn the key switch to the STOP
position.
RUN
RUN
ST
AR
T
START
( e) Close the fuel valve.
OIL SENSOR
(a) The oil sensor detects the fall in oil
level in the crankcase and automatically stops the engine when the oil
level falls below a predetermined level.
(b) When engine has stopped
automatically, switch off generator's
AC circuit breaker, and check the oil
level.
Refill engine oil to the upper level as
instructed on page 7 and restart the
engine.
(c) If the engine does not start by usual
starting procedures, check the oil level.
− 20−
CLOSE
CLOSE
OPEN
Oil sensor
EG781AE ce_GU6837 10.1.25 1:36 PM ページ21
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
EG301A
Incandescent lamp, Heater
2400
Fluorescent lamp, Electric tool
EG781A
EG381A
EG511A
EG711A
EG381AE EG511AE EG711AE EG781AE
2900
4200
5000
6000
1300
1600
2300
2750
3300
Mercury lamp
950
1150
1700
2000
2400
Pump, Compressor
600
700
1050
1250
1500
− 21−
ENGLISH
6. WATTAGE INFORMATION
EG781AE ce_GU6837 10.1.25 1:36 PM ページ22
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.
Allowable No.of strands
Resistance
current
/ strands dia.
Current Amp.
mm2
No.
A
No./mm
Ω/100m
1A
0.75
18
7
30/0.18
2.477
2.5V 8V 12.5V ─
1.27
16
12
50/0.16
1.486
1.5V 5V 7.5V 12V 15V 18V
2.0
14
17
37/0.26
0.952
1V
3.5
12 to 10
23
45/0.32
0.517
─
5.5
10 to 8
35
70/0.32
0.332
─
− 22−
3A
3V
5A
10A 12A 15A
─
─
─
─
8V
10V 12V 15V
1.5V 2.5V 4V
5V 6.5V 7.5V
1V
5V
8A
2V 2.5V 3.5V 4V
5V
Voltage drop
Nominal
cross
A.W.G.
section
EG781AE ce_GU6837 10.1.25 1:36 PM ページ23
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
Increases fuel consumption
●
●
Reduces engine output
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
EG711AE
EG781A
EG781AE
EG301A
EG381A
EG381AE
EG511A
EG511AE
Muffler
cover
Exhaust
outlet
Screw
Spark
arrester
screen
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.
EG301A
EG381A
EG381AE
EG511A
EG511AE
Spark arrester screen
EG711A
EG711AE
EG781A
EG781AE
− 23−
Spark arrester screen
ENGLISH
7. SPARK ARRESTER
EG781AE ce_GU6837 10.1.25 1:36 PM ページ24
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 EMISSIONRELATED 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
(2) Cold start enrichment
system, if applicable
(6) Magneto or electronic
ignition system
(3) Intake manifold, if
applicable
(7) Spark advance/retard
system, if applicable
(5) Spark plug
(8) Exhaust manifold, if
applicable
(9) Hoses, belts,
connectors, and
assemblies
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.
− 24−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ25
Maintenance Items
Every
8 hours
(Daily)
Every
50 hours
(Weekly)
Every
200 hours
(Monthly)
Clean generator and check bolt and nuts
● (Daily)
Check and refill engine oil
● (Refill daily up to upper level)
Change engine oil (*Note1)
● (Initial
20 hours)
Every
500
hours
Every
1000
hours
● (Every
100 hours)
Clean spark plug
● (Every 100 hours)
Clean air cleaner
●
Clean spark arrester
● (Every 100 hours)
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
●
● (Yearly)
Replace fuel lines
●
Overhaul engine (*Note 2)
Check AC receptacles
● (Daily)
Check DC termianl
● (Daily)
Check engine switch
● (Daily)
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−
ENGLISH
Periodic Maintenance Schedule table
EG781AE ce_GU6837 10.1.25 1:36 PM ページ26
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
EG511A, EG511AE
Element
Element
Base
EG711A, EG711AE
EG781A, EG781AE
Element
Base
Bolt
Base
Air cleaner
cover
Air cleaner
cover
− 26−
Air cleaner
cover
EG781AE ce_GU6837 10.1.25 1:36 PM ページ27
ENGLISH
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−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ28
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
confirm its length.
Length when new
In addition, check the brush length if the
generator malfunctions, such as when it is
not generating power or its voltage is low.
10~11mm
Effective brush length
5 mm
− 28−
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 (1.5~2N・m) by
tightening it with the two 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 (3~4N・m) by
tightening it with the two flange bolts
(M5 x 20).
− 29−
Brush holder
Flange bolts
Bracket cover
Flange bolts
ENGLISH
EG781AE ce_GU6837 10.1.25 1:36 PM ページ29
EG781AE ce_GU6837 10.1.25 1:36 PM ページ30
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 enginestarting 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.
− 30−
EG781AE ce_GU6837 10.1.25 1:36 PM ページ31
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 :
Check if choke lever is in its proper
position.
Set the choke lever to "CLOSE"
Check if fuel valve is open.
If closed, open fuel valve.
Check fuel level.
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.
position.
When No Electricity Is Generated at Receptacle :
Check to make sure AC circuit breaker
is in the "ON" position.
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 AC receptacle and DC terminals
for loose connection.
Secure connection if necessary.
Check to see if engine starting was
Turn off switch on the appliance, and
disconnect cable from receptacle.
attempted with appliances already
connected to generator.
Reconnect after generator has been
started properly.
Low power.
Carbon brushes are excessively worn
− 31−
ENGLISH
11. TROUBLESHOOTING
Spark plug
Y
Blu
Slip
ring
ROTOR
GENERATOR
AVR unit
Brn
Brn
Blk
Blu
Blu
Oil sensor switch
Y
Sub coil
STATOR
Ignition coil
Y
ENGINE
Y
− 32−
Brn
Brn
Bridge
diode
AC winding 2
Grn/Y
Y
Y/R
Y
Blk
AC winding 1
Org
DC winding
EG301A (60Hz-120V)
Oil sensor unit
Blk
W
Grn/Y
Blu
Org
Gry
R
Grn/Y
Blk
W
Grn/Y
Blu
R
DC circuit
breaker
Engine switch
Blk
CONTROL BOX
W
AC circuit
breaker
R
PL
X
:
:
:
:
Black
Black/White
Blue
Light blue
Wiring color code
Blk
Blk/W
Blu
LBlu
W
W
W
W
DC12V
DC Output
receptacle
X
X
X
Brn
:
Brn/W :
Grn :
Grn/W :
Grn/Y
Brown
Brown/White
Green
Green/White
Blu
Org
Gry
R
W
:
:
:
:
Orange
Gray
Red
White
Earth
(Ground)
terminal
Y
W/Blk
Grn/Y
Pur
:
:
:
:
Yellow
White/Black
Green/Yellow
Purple
EG781AE ce_GU7037 10.5.10 11:45 AM ページ32
12. WIRING DIAGRAM
Pilot lamp
Y
Spark plug
Blu
Slip
ring
ROTOR
AVR unit
Brn
Brn
GENERATOR
Blk
Blu
Blu
Y
Sub coil
STATOR
Ignition coil
Oil sensor switch
Y
Y
Blk
Grn/Y
Y
Brn
Brn
Bridge
diode
AC
winding 2
AC
winding 1
Y/R
Org
Oil sensor unit
Blk
W
Grn/Y
Blk
W
Grn/Y
Blu
Org
Org
Blu
Gry
R
Gry
R
AC circuit
breaker
R
DC circuit
breaker
AC circuit breaker
R
Blu
PL
CONTROL BOX
Pilot lamp
ENGINE
Y
− 33−
DC winding
W
R
11
8
5
2
Blk
Blk/W
Blu
LBlu
:
:
:
:
R
X
X
X
Blu
30A
W
Org
R
Black
Black/White
Blue
Light blue
Grn/Y
W
W
Brn
:
Brn/W :
Grn :
Grn/W :
Y
X
30A
Grn/Y
W
Gry
Org
Gry
R
W
Grn/Y
Brown
Brown/White
Green
Green/White
DC12V
DC Output
receptacle
Blu
Wiring color code
12
10
9
7
6
4
3 120V
1 120/240
Org
Full power
switch
Grn/Y
Engine switch
Blk
AC circuit
breaker
EG381A (60Hz-120/240V)
:
:
:
:
Grn/Y
Orange
Gray
Red
White
Earth
(Ground)
terminal
:
:
:
:
Yellow
White/Black
Green/Yellow
Purple
ENGLISH
Y
W/Blk
Grn/Y
Pur
EG781AE ce_GU7037 10.5.10 11:45 AM ページ33
Blk
Y
Blu
Slip
ring
ROTOR
GENERATOR
Spark plug
Battery
R
AVR unit
Y
Sub coil
Y
Y
AC
winding 2
AC
winding 1
Y/R
Org
Blk
Blk
STATOR
Y
Blk
Brn
Brn
Ignition coil
Oil sensor switch
Blu
Blu
Grn/Y
Brn
Oil sensor unit
Brn
Bridge
diode
Blk
W
Grn/Y
Blu
Blk
W
Grn/Y
Blu
Org
R
Org
Magnetic switch
Gry
Electric starter
Gry
R
Gry
AC circuit
breaker
Blu
Blu
CONTROL BOX
R
Blk
R
DC circuit
breaker
AC circuit breaker
R
Blu
Pilot lamp
ENGINE
Y
− 34−
DC winding
12
10
9
7
6
4
Blk
Blk/W
Blu
LBlu
:
:
:
:
M+
Black
Black/White
Blue
Light blue
X
Blu
30A
Org
X
X
Brn
:
Brn/W :
Grn :
Grn/W :
R
Grn/Y
R
Blu
Wiring color code
DC12V
DC Output
W receptacle
R
11
8
5
Org
1 120/240V
3 120V
ST
Org
B
Key switch
Gry IG
Full power
switch
2
Fuse
Grn/Y M-
Org
AC circuit
breaker
EG381AE (60Hz-120/240V)
W
Grn/Y
Gry
Y
Org
Gry
R
W
Grn/Y
X
30A
Brown
Brown/White
Green
Green/White
W
W
W
:
:
:
:
Grn/Y
Orange
Gray
Red
White
Y
W/Blk
Grn/Y
Pur
Earth
(Ground)
terminal
:
:
:
:
Yellow
White/Black
Green/Yellow
Purple
EG781AE ce_GU7037 10.5.10 11:45 AM ページ34
Charge coil
R
Blk
Sub coil
STATOR
AVR unit
Grn
Grn
Slip ring
ROTOR
GENERATOR
Spark plug
ENGINE
W
W
W
Ignition coil
Blu
Blu
Y
Grn/Y
Brn
Blk
W
Blk
W
Grn/Y
Grn/Y
Org
Org
Blu
Gry
R
Gry
R
Oil sensor unit
Blu
Bridge
diode
Brn
AC
winding 2
AC
winding 1
Y/R
Org
Blk
Blu
AC circuit
breaker
CONTROLBOX
Pilot lamp
DC circuit
breaker
PL
W
Blu 11
8
5
2
Blu
Blk
Blk/W
Blu
LBlu
:
:
:
:
Black
Black/White
Blue
Light blue
Wiring color code
DC12V
DC Output
receptacle
12
10
9
7
6
3 120V Only
4
1 120/240V
Full power
switch
W
X
W
W
Brn
:
Brn/W :
Grn :
Grn/W :
X
X
Y
30A
Grn/Y
Engine switch
Blk
AC circuit
breaker
AC circuit
breaker
Oil sensor switch
Blu
Blu
− 35−
DC winding
AC circuit
breaker
X
X
X
Org
Gry
R
W
Grn/Y
W
W
W
Grn/Y
30A
Brown
Brown/White
Green
Green/White
AC circuit
breaker
EG511A, EG711A, EG781A (60Hz-120/240V)
:
:
:
:
Grn/Y
Orange
Gray
Red
White
Earth
(Ground)
terminal
:
:
:
:
Yellow
White/Black
Green/Yellow
Purple
ENGLISH
Y
W/Blk
Grn/Y
Pur
EG781AE ce_GU7037 10.5.10 11:45 AM ページ35
Battery
R
Slip
ring
ROTOR
R
Blk
AVR unit
Blu
Sub coil
Y
Blk
Grn/Y
Blu
AC
winding 2
AC
winding 1
Y/R
Org
STATOR
Grn
Grn
GENERATOR
Spark plug
Blk
W
W
Ignition coil
Oil sensor switch
Blu
W
Oil sensor unit
Brn
Brn
Bridge
diode
Blk
W
Grn/Y
Blu
Blk
W
Grn/Y
Org
Magnetic switch
Org
Electric starter
Gry
Blu
R
Charge coil
Gry
R
Blu
Blu
Gry
AC circuit
breaker
Blu
Pilot lamp
DC circuit
breaker
PL
CONTROL BOX
W
12
10
9
7
6
4
Blu
3 120VONLY
1 120/240V
Blk
Blk/W
Blu
LBlu
:
:
:
:
Black
Black/White
Blue
Light blue
Wiring color code
DC12V
DC Output
receptacle
Blu 11
8
5
2
ST
X
X
X
30A
Y
W
W
Brn
:
Brn/W :
Grn :
Grn/W :
W
X
Brown
Brown/White
Green
Green/White
Grn/Y
M+
Org
B
Key switch
IG
Gry
Fuse
M-
Org
Grn/Y
Full power
switch
R
Blk
AC circuit
breaker
AC circuit
breaker
ENGINE
Blu
− 36−
DC winding
AC circuit
breaker
AC circuit
breaker
EG511AE, EG711AE, EG781AE (60Hz-120/240V)
X
X
W
W
Org
Gry
R
W
30A
:
:
:
:
Grn/Y
Orange
Gray
Red
White
Grn/Y
W
Grn/Y
Y
W/Blk
Grn/Y
Pur
Earth
(Ground)
terminal
:
:
:
:
Yellow
White/Black
Green/Yellow
Purple
EG781AE ce_GU7037 10.5.10 11:45 AM ページ36
ISSUE EMD-GU7037
Makita Corporation
3-11-8, Sumiyoshi-cho
Anjo, Aichi 446-8502 Japan
PRINTED IN JAPAN
May 2010
IMPRESO EN JAPÓN
Mayo 2010