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Makita EG301A Instructions For Use Manual Download Page 41

−

36

−

PL

GENERA

T

OR

CONTROL

 BOX

ENGINE

Org

Y/R

Blk

Blk

Ignition coil

Oil sensor switch 

Spark plug

Oil sensor unit

Y

AC

winding 2

AC

winding 1

Blu

Blu

Grn/Y

Brn

Blu

Blu

R

Grn

Grn

W

W

W

Brn

ROT

OR

S

TAT

O

R

Slip 

ring

Sub coil

DC winding

AV

R

 unit

Bridge 

diode

RR

Blu

Blu

Gry

Grn/Y

W

W

Blk

Blk

Org

Gry

Org

Grn/Y

Battery

Electric starter

Magnetic switch 

Charge coil

Key switch

Fuse

M+

Full power 

switch

IG

M-

ST

B

Blu

Blu

1

3

4

6

7

9

10

12

2

5

8

11

120/240V

120VONL

Y

DC Output 

receptacle

DC circuit 

breaker

DC12V

Earth 

(Ground) 

terminal

Pilot lamp

AC circuit 

breaker

Blu

Blu

Blk

R

W

Grn/Y

Grn/Y

Grn/Y

Grn/Y

AC circuit 

breaker

AC circuit 

breaker

AC circuit 

breaker

AC circuit 

breaker

30A

30A

W

X

W

X

W

X

W

X

W

X

W

X

Y

Blu

Gry

Gry

R

Blk

Org

Org

Grn/Y

EG51

1AE, EG71

1AE, EG781AE

(60Hz-120/240V)

Blk : 

Black

Wi

ring color code

Blk/W : 

Black/White

Blu : 

Blue

LBlu : 

Light 

blue

Brn : 

Brown

Brn/W : 

Brown/White

Grn : 

Green

Grn/W : 

Green/White

Org : 

Orange

Gry : 

Gray

R : 

Red

W : 

White

Y : 

Y

ellow

Grn/Y : 

Green/Y

ellow

W/Blk : 

White/Black

Pur : 

Purple

EG781AE ce̲GU7037  10.5.10  11:45 AM  ページ36

Summary of Contents for EG301A

Page 1: ...3ZZ9990516 EG series EG301A EG381A EG381AE EG511A EG511AE EG711A EG711AE EG781A EG781AE ...

Page 2: ...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 Notice This hangtag must remain on this engine or piece of equipment and only be remo...

Page 3: ......

Page 4: ... operate the generator before you have read and understood the instructions Failure to do so could result in death personal injury or equipment damage 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 he...

Page 5: ...CATIONS 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 ...

Page 6: ...ator 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 oi...

Page 7: ... 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 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 ap...

Page 8: ...Automotive Unleaded Gasoline Fuse less circuit breaker V Rated current 12 A Safety device type 8 3 DC Output Rated power factor 1 0 AVR type 120 240 60 120 60 EG381A EG381AE EG511A EG511AE EG711A EG711AE EG301A EX30D EX35D 22 0 27 5 1 EX17D 287 404 169 Brush self exciting 2 poles single phase 2900 V Hz Rated voltage Frequency Safety device type Fuse less circuit breaker 2400 4200 EX21D 675 925 2 6...

Page 9: ...ngine switch Choke lever Oil drain plug Oil gauge oil filler Spark plug cap Air cleaner Exhaust outlet Tank cap Fuel strainer Fuel valve Muffler cover Recoil starter Recoil starter handle Control panel EG301A EG381A EG381AE EG511A EG511AE ...

Page 10: ...SH Control panel Fuel tank Fuel gauge Engine switch Recoil starter handle Choke lever Oil gauge oil filler Spark plug cap Air cleaner Muffler Tank cap Recoil starter Oil drain plug EG711A EG711AE EG781A EG781AE ...

Page 11: ...e 30A AC receptacle 20A Engine switch Electric starter model Engine switch Pilot lamp Earth ground terminal AC circuit breaker AC circuit breaker DC receptacle DC circuit breaker Engine switch Key switch AC receptacle 30A Pilot lamp Full power switch AC circuit breaker Full power switch AC receptacle 30A Earth ground terminal Idle Control Switch DC receptacle AC receptacle 20A Electric starter mod...

Page 12: ...en checking oil level Change oil if contaminated See How To Maintenance 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 Ambient temperature Single...

Page 13: ...s Otherwise fire accident may occur CHECK ENGINE FUEL 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 WARNING WARNING NOTE THIS ENGINE IS...

Page 14: ...eter 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 WARNING BATTERY INSTALLATION Electric Starter Model Recommended Battery Type Lead acid battery Capacity A...

Page 15: ...ge 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 B...

Page 16: ...he AC circuit breaker to the position OFF c Open the fuel valve d Set choke lever to close if the engine is cold STARTING THE GENERATOR Check the oil level before each operations as outlined by the article CHECK ENGINE OIL CAUTION ON OFF OPEN CLOSE CLOSE Choke lever CLOSE OPEN ON OFF OFF ...

Page 17: ...he 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 RUN STOP STOP RUN START START 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 secon...

Page 18: ... 13 ENGLISH 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 ...

Page 19: ...iance 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 WARNING 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 o...

Page 20: ...sition Be sure to ground the generator if the connected electrical device Is grounded WARNING TWIST up to 30A up to 20A NEMA 5 20R NEMA L14 30R NEMA 5 20P NEMA L14 30P GFCI Ground Fault Circuit Interrupter Receptacle duplex REC1 Locking Receptacle REC4 Style Ampere Receptacle AC plug Description up to 30A NEMA L5 30R NEMA L5 30P Locking Receptacle REC3 The duplex 120V receptacle is protected by a ...

Page 21: ...ed 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 If the RESET button pops out during operation stop the generator immediately and call a qualified electrician for che...

Page 22: ... Change the FULL POWER SWITCH after turning the AC circuit breaker to OFF CAUTION 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 Disconnec...

Page 23: ...d 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 ...

Page 24: ...ry 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 CAUTION Battery Charging Procedures 1 Stop engine 2 Remove all connections from battery 3 Insert the plug of ex...

Page 25: ... switch to the STOP position e Close the fuel valve OIL SENSOR 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 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 e...

Page 26: ...quire 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...

Page 27: ...proximate 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 A W G Allowable current No of strands strands dia Resistance Current Amp No mm Ω 100m mm2 No A 1A 3A 5A 8A 10A 12A 15A 0 75 18 7 30 0 18 2 477 2 5V 8V 12 5V Voltage drop 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 1...

Page 28: ...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 Spark arrester screen Screw Muffler Screw Muffler cover Exhaust outlet Spark arrester screen Clean the spark arrester screen Use...

Page 29: ...onsists of the following parts 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 1 Carburetor and internal parts 2 Cold start enric...

Page 30: ...0 hours Every 200 hours Monthly Every 50 hours Weekly Every 8 hours Daily Clean generator and check bolt and nuts Daily Daily Yearly Daily Daily Check and refill engine oil Change engine oil Note1 Clean spark plug Clean air cleaner Replace air cleaner element Clean fuel filter Check and replace carbon brushes Remove carbon from cylinder head Note 2 Check and adjust valve clearance Note 2 Clean and...

Page 31: ...A EG381A EG381AE EG511A EG511AE EG711A EG711AE EG781A EG781AE 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...

Page 32: ...e 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 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 Spark plug BR 6HS NGK ...

Page 33: ...t is not generating power or its voltage is low 5 mm 10 11mm Effective brush length Length when new 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 be...

Page 34: ...n remove the brush 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 Flange bolts Brush holder Bracket cover Flange bolts Slip ring Brush ...

Page 35: ...ually deteriorate making engine starting difficult 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 generat...

Page 36: ...closed open fuel valve If empty refill fuel tank making sure not to overfill If connected turn off the power switch on the connected appliance and unplug If loose push spark plug cap back into place Remove spark plug and clean electrode Turn engine switch to ON Check to make sure AC circuit breaker is in the ON position Check AC receptacle and DC terminals for loose connection Check to see if engi...

Page 37: ...inding AVR unit Bridge diode DC Output receptacle DC circuit breaker DC12V Earth Ground terminal Pilot lamp Blk Blk AC circuit breaker Org Grn Y Blu Grn Y GENERATOR CONTROL BOX ENGINE Engine switch W X W X W X W X EG301A 60Hz 120V Blk Black Wiring color code Blk W Black White Blu Blue LBlu Light blue Brn Brown Brn W Brown White Grn Green Grn W Green White Org Orange Gry Gray R Red W White Y Yellow...

Page 38: ...d terminal Pilot lamp Blk Blk AC circuit breaker AC circuit breaker Org Gry Org Grn Y Blu Blu Grn Y GENERATOR CONTROL BOX ENGINE Engine switch R Blu Org Grn Y Gry Grn Y Grn Y R R Org R 1 3 4 6 7 9 10 12 2 5 8 11 120 240 120V Full power switch 30A 30A W X W X W X W X Y AC circuit breaker EG381A 60Hz 120 240V Blk Black Wiring color code Blk W Black White Blu Blue LBlu Light blue Brn Brown Brn W Brow...

Page 39: ... 4 6 7 9 10 12 2 5 8 1 1 120 240V 120V DC Output receptacle DC circuit breaker DC12V Earth Ground terminal Pilot lamp AC circuit breaker AC circuit breaker Blu Blu Blk R W Grn Y Grn Y Grn Y Blk Gry R Blk Org Org Grn Y Gry Grn Y Org R Gry Org Blu R R Blu Org R CONTROL BOX GENERATOR ENGINE AC circuit breaker 30A 30A W X W W X X W X Y EG381AE 60Hz 120 240V Blk Black Wiring color code Blk W Black Whit...

Page 40: ...p Blk Blk AC circuit breaker AC circuit breaker AC circuit breaker AC circuit breaker AC circuit breaker Org Gry Org Grn Y Blu Blu Grn Y GENERATOR CONTROLBOX ENGINE Engine switch Blu Grn Y Grn Y 30A 30A W X W W X X W X W X W X 1 3 4 6 7 9 10 12 2 5 8 11 120 240V 120V Only Full power switch Y EG511A EG711A EG781A 60Hz 120 240V Blk Black Wiring color code Blk W Black White Blu Blue LBlu Light blue B...

Page 41: ... S T B Blu Blu 1 3 4 6 7 9 10 12 2 5 8 1 1 120 240V 120VONLY DC Output receptacle DC circuit breaker DC12V Earth Ground terminal Pilot lamp AC circuit breaker Blu Blu Blk R W Grn Y Grn Y Grn Y Grn Y AC circuit breaker AC circuit breaker AC circuit breaker AC circuit breaker 30A 30A W X W X W X W X W X W X Y Blu Gry Gry R Blk Org Org Grn Y EG511AE EG711AE EG781AE 60Hz 120 240V Blk Black Wiring colo...

Page 42: ...Makita Corporation 3 11 8 Sumiyoshi cho Anjo Aichi 446 8502 Japan ISSUE EMD GU7037 PRINTED IN JAPAN May 2010 IMPRESO EN JAPÓN Mayo 2010 ...

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