MAKITA G4100R (01) PDF MANUAL

• 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.
• Do not place flammable materials near the generator. Be careful not to place fuel, matches, gunpowder, oily cloths, straw, trash, or any other flammables near the generator.

• Do not operate the generator inside a room, cave, tunnel, or other insufficiently ventilated area. Always operate it in a well-ventilated area.
• Keep the generator at least 1 meter (3 feet) away from any structure or building during use.
• If the generator must be used indoors, the area must be well-ventilated and extreme caution must be taken regarding the discharge of exhaust gases.
• Do not enclose the generator nor cover it with a box. Remove any covers before use.
• Operate the generator on a level surface to ensure proper lubrication and prevent fuel spillage or tipping. Do not operate on a steep incline or slope.
• Keep the area clear of flammables or other hazardous materials.
• Keep the exhaust pipe clear of foreign objects.
• Do not block generator air vents with paper or other material.

• Pay attention to wiring or extension cords. If a wire is under the generator or contacts a vibrating part, it may break, causing fire, burnout, or shock hazard. Replace damaged cords immediately.
• Do not operate in rain, wet or damp conditions, or with wet hands to avoid severe electric shock. If wet, wipe and dry the generator well before starting. Do not pour water over it or wash it with water.
• Follow all necessary electrical grounding procedures. Failure to do so can be fatal. (See “How do I ground the generator?”)
• Do not connect the generator to a commercial power line. Use a transfer switch for connecting to a domestic circuit.
• Use only “LISTED” extension cords marked “For Outdoor Use” when operating tools or appliances outdoors. Store cords in a dry, well-ventilated area.
• Make sure the appliance is switched OFF before connecting it to the generator.
• Be sure to ground the generator if the connected appliance is grounded. Failure to ground the unit may lead to electrical shock.

• No smoking while handling the battery. It emits flammable hydrogen gas.
• Keep the area well-ventilated and keep open flames/sparks away.
• Turn the starter switch to “STOP” when mounting or dismounting.
• When mounting, connect the positive (+) cable first, then the negative (-) cable.
• When dismounting, disconnect the negative (-) cable first.
• Be careful not to short battery cables.
• Ensure connections are correct to avoid generator damage. Red cable to positive (+), Black cable to negative (-).
• Tighten terminal bolts and nuts securely.
• Disconnect battery cables when charging the battery.
• Use a battery of the recommended capacity (12V-24AH or larger).

• The engine becomes extremely hot during and after operation.
• Keep combustible materials well away from the generator area.
• Be very careful not to touch any hot engine parts, especially the muffler area, to avoid serious burns.

Before checking or refilling oil, ensure the generator is on a stable, level surface with the engine stopped.

1. Remove the oil filler cap/gauge.
2. Wipe the gauge clean.
3. Insert the gauge back into the filler neck *without screwing it in*.
4. Remove the gauge and check the oil level.
5. If the oil level is below the lower level line, refill with recommended oil to the upper level line.
6. Replace the oil filler cap securely.
7. Change oil if it appears contaminated.

Oil Capacity:

• G2800R: 0.17 US-gal. (0.65 liter)
• G4100R, G4101R: 0.26 US-gal. (1.0 liter)
• G6100R, G6101R: 0.32 US-gal. (1.2 liter)

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 based on the chart below:

WARNING: Do not refuel while smoking or near open flame or other potential fire hazards. Fire accident may occur. Make sure you review all warnings to prevent fire hazard.

• Do not refill tank while engine is running or hot.
• Close fuel cock before refueling.
• 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.

Procedure:

1. Check fuel level using the fuel level gauge on top of the tank.
2. If fuel level is low, remove the tank cap.
3. Refill with automotive unleaded gasoline. This engine is certified to operate on automotive unleaded gasoline.
4. Be sure to use the fuel filter screen located in the fuel filler neck.
5. Replace the tank cap securely.

Fuel Tank Capacity:

• G2800R: 3.17 US-gal. (12.0 liter)
• G4100R, G4101R: 4.39 US-gal. (16.6 liter)
• G6100R, G6101R: 5.68 US-gal. (21.5 liter)

• 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.

WARNING: Death, personal injury and/or property damage may occur unless instructions are followed carefully. Use a battery of recommended capacity (12V-24AH or larger).

1. Turn the starter switch to the “STOP” position.
2. Connect the positive (+) RED CABLE to the positive (+) battery terminal first.
3. Connect the negative (-) BLACK CABLE to the negative (-) battery terminal. Be careful not to short the cables.
4. Tighten the terminal bolts and nuts securely to prevent loosening from vibration.

Note: Incorrect connection will damage the generator. When disconnecting, remove the negative (-) cable first.

• To ground the generator to the earth, connect the grounding lug (terminal marked with ground symbol) of the generator to a grounding spike driven into the earth or to a conductor which has already been grounded to the earth.
• If such a grounding conductor or electrode is unavailable, connect the grounding lug of the generator to the grounding terminal of the electric tool or appliance being used.

WARNING: Be sure to ground the generator if the connected appliance is grounded. Failure to ground unit may lead to electrical shock.

[CAUTION] Check the oil level before each operation.

1. Turn the engine switch to the “ON” position.
2. Turn the no-fuse breaker (AC Breaker) to the “OFF” position.
3. Open the fuel cock (turn lever down to “OPEN”).
4. If the engine is cold, pull the choke knob fully out to the “CLOSE” position.
5. Pull the recoil starter handle slowly until resistance is felt (the “compression” point).
6. Return the handle to its original position and then pull swiftly. Do not pull the rope fully out.
7. After starting, allow the starter handle to return to its original position while still holding the handle.
8. If the engine fails to start after several attempts, repeat the procedures with the choke knob returned to the “OPEN” position.
9. After the engine starts, gradually push the choke knob back to the “OPEN” position as the engine warms up.
10. Warm up the engine without a load for a few minutes.

[CAUTION] Check the oil level before each operation.

1. Turn the no-fuse breaker (AC Breaker) to the “OFF” position.
2. Open the fuel cock (turn lever down to “OPEN”).
3. If the engine is cold, pull the choke knob fully out to the “CLOSE” position.
4. Insert the key into the key switch.
5. Turn the key clockwise to the “RUN” position.
6. Turn the key further clockwise to the “START” position to engage the starting motor. Release the key back to the “RUN” position once the engine starts.
   [CAUTION]
   • Do not run the starting motor for over 5 seconds continuously. If the engine fails to start, return the key to “RUN”, wait about 10 seconds, then try again.
   • Do not turn the key switch to “START” when the engine is running.
7. After the engine starts, gradually push the choke knob back to the “OPEN” position as the engine warms up.
8. Warm up the engine without a load for a few minutes.

Note: When starting the engine by recoil starter on electric start models, set the key switch to the “ON” (or “RUN”) position and pull the starter handle as per recoil start instructions.

WARNING:

• Make sure 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.

Procedure:

1. Start the engine and allow it to warm up.
2. Check the pilot lamp for proper voltage indication. If the generator does not produce the specified voltage, consult a Makita service center.
3. Ensure the switch(es) of the electrical appliance(s) are OFF.
4. Insert the plug(s) of the appliance(s) into the AC receptacle(s).
   • Check the amperage rating of the receptacles. Do not exceed the specified amperage.
   • Ensure the total wattage of all connected appliances does not exceed the rated output of the generator.
5. Turn the no-fuse breaker (AC Breaker) to the “ON” position.
6. Switch on the electrical appliance(s).

[CAUTION]

• The DC output is for charging 12V automotive-type batteries only.
• Confirm the battery is 12V before connecting.
• Connect the charging cables to the battery terminals *before* connecting them to the generator DC terminals.
• Connect the positive (+) lead to the positive (+) battery terminal, and the negative (-) lead to the negative (-) battery terminal. Do not reverse the polarity.
• Do not allow the positive (+) and negative (-) clips to touch each other.
• Disconnect the charging cables from the battery when the engine is stopped.
• Start the engine first, then connect the charging cables to the DC terminals on the generator.
• Do not start the engine of a vehicle while the generator is connected to the battery.
• The DC circuit breaker will turn OFF automatically if the current exceeds the rated value. Turn it ON again after checking the cause.

Procedure:

1. Ensure the battery is a 12V automotive type.
2. Connect the charging cable’s positive (+) clip (usually red) to the positive (+) battery terminal.
3. Connect the charging cable’s negative (-) clip (usually black) to the negative (-) battery terminal.
4. Start the generator engine.
5. Connect the charging cable plug to the DC output terminal on the generator control panel.
6. Monitor the charging process (specific gravity of electrolyte should reach 1.26-1.28). Overcharging can damage the battery.
7. When charging is complete, disconnect the charging cable from the generator first, then from the battery.

The Idle Control system automatically lowers the engine speed when no load is connected or when the load is disconnected, reducing noise and fuel consumption. When a load is connected, the engine returns to the proper speed.

• ON Position: Idle control system is activated. Recommended for minimizing fuel consumption when load changes frequently.
• OFF Position: Idle control system is deactivated. Engine runs at rated speed continuously. Use this position when starting the generator or when using loads that require constant full power (like some motors or loads sensitive to voltage/frequency changes).

Note: The idle control system may not work effectively if the electrical appliance cycles on and off rapidly.

This switch allows selection between using the full generator output through the 120V receptacles or splitting the output for 120V/240V operation.

• 120V Position (Full Power): The total rated output is available through the 120V receptacles only. The 120V/240V twist-lock receptacle is disabled. Use this when maximum 120V power is needed.
• 120V/240V Position: The generator output is configured for simultaneous 120V and 240V use via the appropriate receptacles. The maximum current available from any single 120V receptacle may be reduced in this mode (typically half the generator’s total rated amperage).

Note: Always set the switch *before* starting the engine or connecting loads. Do not switch while loads are connected or the engine is running.

1. Turn off or disconnect all connected electrical appliances.
2. Turn the AC circuit breaker (no-fuse breaker) to the “OFF” position.
3. Recoil Start Models: Turn the engine switch to the “OFF” position.
4. Electric Start Models: Turn the key switch to the “STOP” position.
5. Close the fuel cock (turn lever up to “CLOSE”).

Ensure the total wattage of all appliances connected simultaneously does not exceed the generator’s rated output.

1. Check the wattage requirement listed on each appliance’s nameplate or in its manual.
2. For motors or appliances with motors (like power tools, refrigerators), the starting wattage can be significantly higher (2 to 5 times) than the running wattage. Use the higher starting wattage figure for calculations.
3. Add up the wattage requirements of all appliances intended to run at the same time. This total should be less than or equal to the generator’s rated wattage.
4. Convert amps to watts if needed: Watts = Volts x Amps (Use 120V or 240V as appropriate).

Refer to the Wattage Estimation Guide for typical appliance power needs.

Use this guide for estimation only. Check the actual wattage on your appliance.

The spark arrester is a device fitted to the muffler to prevent sparks from exiting the exhaust. It requires periodic cleaning to maintain its efficiency and prevent clogging, which can reduce engine power.

Maintenance Procedure:

[CAUTION] The engine and muffler will be very hot after operation. Allow them to cool completely before servicing the spark arrester.

1. Remove the screws holding the muffler protector (cover) and remove the protector.
2. Remove the screws holding the spark arrester to the muffler.
3. Carefully pull the spark arrester screen out of the muffler.
4. Clean the spark arrester screen using a wire brush. Be careful not to damage the screen. Replace the screen if it is damaged.
5. Reinstall the spark arrester screen into the muffler.
6. Reinstall the screws holding the spark arrester.
7. Reinstall the muffler protector and secure it with its screws.

Clean the spark arrester every 100 hours of operation or as specified in the maintenance schedule.

Regular maintenance is essential for safety, performance, and emission control.

Notes:

1. Service more frequently when used in dusty areas.
2. These items should be serviced by an authorized dealer, unless the owner has the proper tools and is mechanically proficient.

[CAUTION] Drain the oil while the engine is still warm to assure rapid and complete draining. Avoid contact with hot oil.

1. Place the generator on a level surface.
2. Warm up the engine for a few minutes, then stop it.
3. Remove the oil filler cap.
4. Place an oil pan under the engine. Remove the oil drain plug (located at the base of the engine).
5. Allow the oil to drain completely.
6. Check the drain plug, gasket, and rubber seal. Replace if damaged. Reinstall the drain plug securely.
7. Refill the crankcase with the recommended type and amount of fresh oil (refer to “How do I check the engine oil?” for capacity and type). Check the level using the oil filler cap/gauge (do not screw in when checking).
8. Reinstall the oil filler cap securely.
9. Dispose of used oil responsibly. Do not pour it on the ground or down a drain.

[CAUTION] Never run the engine without the air cleaner element. Rapid engine wear will result.

1. Unsnap the air cleaner cover clips or remove the wing nut securing the cover. Remove the cover.
2. Remove the air cleaner element(s) (typically a foam pre-filter and/or a paper main element).
3. Foam Element: Wash it in solvent and dry it thoroughly. Then saturate it with clean engine oil and squeeze out the excess oil.
4. Paper Element: Tap the element lightly several times on a hard surface to remove excess dirt, or blow compressed air (not exceeding 30 psi) through the filter from the inside out. Never try to brush off dirt; brushing will force dirt into the fibers. Replace the paper element if it is excessively dirty or damaged.
5. Wipe dirt from the inside of the air cleaner body and cover using a moist rag. Be careful to prevent dirt from entering the carburetor inlet.
6. Reinstall the cleaned or new element(s). Ensure the element seals properly.
7. Reinstall the air cleaner cover and secure it with the clips or wing nut.

Service the air cleaner more frequently in dusty conditions.

1. Allow the engine to cool.
2. Disconnect the spark plug cap.
3. Clean any dirt from around the spark plug base.
4. Use a spark plug wrench to remove the spark plug.
5. Visually inspect the spark plug. Discard it if the insulator is cracked or chipped, or if the electrodes are heavily worn.
6. Clean the spark plug with a wire brush if it is to be reused.
7. Measure the spark plug gap with a feeler gauge. The correct gap is typically 0.6 – 0.7 mm (0.024 – 0.028 in). Adjust the gap if necessary by carefully bending the side electrode.
8. Check that the spark plug washer is in good condition.
9. Thread the spark plug in by hand to prevent cross-threading.
10. Tighten the spark plug with a spark plug wrench. If installing a new plug, tighten 1/2 turn after the washer contacts the seat. If reinstalling a used plug, tighten 1/8 – 1/4 turn after the washer contacts the seat.
11. Reconnect the spark plug cap.

Recommended Spark Plugs: NGK BPR4HS or CHAMPION RL95YC (or equivalent).

[CAUTION] The spark plug must be securely tightened. An improperly tightened plug can become very hot and damage the engine.

Proper storage preparation is essential to keep your generator trouble-free and looking good.

1. Clean the Generator: Wash the generator, including the engine cooling fins. Clean dust and dirt from around the muffler and cylinder. Touch up any damaged paint and coat areas that might rust with a light film of oil.
2. Drain the Fuel:
   • Drain the fuel tank completely.
   • Close the fuel cock. Drain the fuel from the carburetor by loosening the carburetor drain screw until fuel flows out. Collect the drained fuel in a suitable container. Retighten the drain screw.
   • WARNING: Gasoline is flammable and explosive. Do not smoke or allow flames/sparks nearby. Drain into an approved container outdoors.
3. Engine Oil: Change the engine oil.
4. Cylinder Lubrication: Remove the spark plug. Pour about one teaspoon of clean engine oil into the cylinder. Pull the recoil starter slowly several times to distribute the oil. Reinstall the spark plug.
5. Storage Location: Cover the generator and store it in a dry, well-ventilated area, away from open flames or sparks (like those from water heaters or clothes dryers). Ensure the storage area is clean and free of dust.
6. Battery (Electric Start Models): Remove the battery. Store it in a cool, dry place. Recharge the battery once a month.

If storing for a very long time, after performing the steps above, pull the recoil starter slowly until resistance is felt (compression stroke). This closes the valves, protecting them from rust and corrosion.