Contents

Yamaha EDL7000SDE, EDL11000SDE Owner's Manual PDF

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Summary of Content for Yamaha EDL7000SDE, EDL11000SDE Owner's Manual PDF

Generator

LIT-19626-01-83 9CN-28199-10

EDL7000SDE EDL11000SDE

OWNERS MANUAL

Read this manual carefully before operating this machine.

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Read this manual carefully before operating this machine. This manual should stay with this machine if it is sold.

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INTRODUCTION

Congratulations on your purchase of your new Yamaha. This manual will provide you with a good basic understanding of the operation and mainte- nance of this machine. If you have any questions regarding the operation or maintenance of your machine, please consult a Yamaha dealer.

EDL7000SDE EDL11000SDE

OWNERS MANUAL 2012 by Yamaha Motor Corporation, U.S.A.

1st Edition, March 2012 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.

is expressly prohibited. Printed in Japan.

P/N LIT-19626-01-83

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Particularly important information is distin- guished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messag- es that follow this symbol to avoid pos- sible injury or death.

WARNING A WARNING indicates a hazardous situ- ation which, if not avoided, could result in death or serious injury.

NOTICE

A NOTICE indicates special precau- tions that must be taken to avoid dam- age to the machine or other property.

TIP A TIP provides key information to make procedures easier or clearer.

WARNING PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE MACHINE.

TIP 9 Yamaha continually seeks advance-

ments in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your engine and this manual. If there is any question concerning this manu- al, please consult a Yamaha dealer.

9 This manual should be considered a permanent part of this engine and should remain with this engine when resold.

* Product and specifications are subject to change without notice.

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CONTENTS SAFETY PRECAUTIONS .................................................................................... 1

SERVICING OF GENERATOR ................................................................................ 9

SPECIFICATION ..................................................................................................... 10

NOMENCLATURE ...................................................................................................11

GROUND FAULT CIRCUIT INTERRUPTER (GFCI) RECEPTACLE ..................... 13

PREPARATION TO SUPPLY THE ELECTRIC POWER ........................................ 15

CONNECTING THE LOAD ......................................................................................17

PRE-OPERATION CHECK..................................................................................... 18

OPERATING THE GENERATOR ........................................................................... 21

SERVICE INTERVALS ........................................................................................... 25

PERIODIC SERVICE .............................................................................................. 27

TRANSPORTING / STORAGE .............................................................................. 39

TROUBLESHOOTING ........................................................................................... 40

AUTOMATIC START/STOP UNIT (A S/S UNIT) .................................................... 42

WIRING DIAGRAM ................................................................................................. 43

WARRAANTY ......................................................................................................... 45

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1 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS 8 To operate the machine safely, be sure to follow the instructions below.

DANGER To avoid personal injury: 8 Hazard of being caught up in the machine: Do

not touch any rotating parts. 8 Do not use or charge the battery if its fluid

level stands below the LOWER mark. Otherwise, the component parts may

deteriorate earlier than expected, which may shorten the service life or cause an explosion. Immediately, add distilled water until the fluid level is between the UPPER and LOWER levels. (for only refillable battery)

WARNING To avoid personal injury: 8 Exhaust gas poisoning hazard: Do not use

the machine in any poorly-ventilated place such as indoors and tunnels. 8 Exhaust gas poisoning and fire hazard:

Do not direct the exhaust to people and buildings. 8 Electric shock hazard: Do not touch the

machine with wet hands. 8 Electric shock hazard: Do not touch the

terminals and sockets while the machine is running. 8 Electric shock and injury hazard: Do not

check and service the machine while it is running. 8 Electric shock and injury hazard: Do not

tamper with the machine. 8 Fire hazard: Flames prohibited. Keep the

machine more than 1 m (3 feet) away from flammable materials. 8 Electric shock hazard: Do not use the

machine in the rain.

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2SAFETY PRECAUTIONS

WARNING To avoid personal injury: 8 Electric shock and fire hazard: Do not

connect the machine to any indoor (commercial) power outlet.

8 Electric shock and injury hazard: Do not allow children to run the machine.

8 Electric shock and injury hazard: Turn off the circuit breaker before starting the machine.

8 Injury hazard: Do not touch the muffler. 8 Injury hazard: Do not run the machine tilted. 8 Injury hazard: Do not move the machine

while it is running. 8 Fire hazard: Stop the engine before adding

fuel. 8 Fire hazard: Do not enclose the machine, nor

cover it with a box or the like. 8 Fire hazard: Pay attention to the type and

amount of fuel. 8 Do not get the warning label dirty or peeled

off. 8 Be sure to hand over the operation manual to

any other operator. 8 Electric shock hazard: Ground the machine

using the ground terminal on the control panel.

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3 SAFETY PRECAUTIONS

WARNING To avoid personal injury: 8 Anti-freeze contains poison. Wear rubber

gloves to avoid personal injury. In case of contact with skin, wash it off immediately. 8 DO NOT mix different types of Anti-freeze.

The mixture can produce chemical reaction causing harmful substances. Use approved Anti-freeze. 8 Be mindful of the environment and the

ecology. Before draining any fluids, find out the correct way of disposing of them. Observe the relevant environmental protection regulations when disposing of oil, fuel, coolant, brake fluid, filters and batteries. 8 When draining fluids from the engine, place

some container underneath the engine body. 8 DO NOT pour waste onto the grounds, down

a drain, or into any water source.

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4SAFETY PRECAUTIONS

WARNING To avoid personal injury: 8 When checking engine or servicing, place the

engine on a wide and level ground. DO NOT work on anything that is supported ONLY by lift jacks or a hoist. Always use blocks or correct stands to support the engine before servicing.

8 Detach the battery from the engine before conducting service. Put a DO NOT OPERATE! tag in the starter switch (key) to avoid accidental starting.

8 To avoid sparks from an accidental short circuit always disconnect the batterys ground cable (-) first and connect it last.

8 Be sure to stop the engine and remove the key when conducting daily and periodic maintenance, servicing and cleaning.

8 Check or conduct maintenance after the engine, coolant, muffler, or muffler cover have been cooled off completely.

8 Always use the appropriate tools and jig- fixture in good condition when performing any service work. Make sure you understand how to use them before service.

8 Use ONLY correct engine barring techniques for manually rotating the engine. DO NOT attempt to rotate the engine by pulling or prying on the cooling fan and V-belt. This practice can cause serious personal injury or premature machine damage to the cooling fan.

8 Replace fuel pipes and lubricant pipes with their hose clamps every 2 years or earlier whether they are damaged or not. They are made of rubber and are aged gradually.

8 When servicing is performed together by two or more persons, take care to perform all work safely.

8 Keep first aid kit and fire extinguisher handy at all times.

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5 SAFETY PRECAUTIONS

DANGER AND WARNING LABELS Pay special attention to all labels on the generator. Refer to following representations for labels used on the EDL Series Generator. Labels are available individually from a Yamaha dealer.

(1) Part No. G3102-88381

(3) Part No. G3102-50902

ULTRA LOW SULFUR DIESEL FUEL ONLY

(5) Part No. G3102-88471 (EDL7000)

(2) Part No. G3102-88391

(4) Part No. G3102-88411

(6) Part No. 5450 806 1000

1. DO NOT SWING WHILE LIFTING. 2. NEVER USE THE HOOK WHEN THE BONNET IS REMOVED OR WHEN ANY BOLTS ARE LOOSE.

TO AVOID PERSONAL INJURY :

WARNING

(5) Part No. G3112-88471 (EDL11000)

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6SAFETY PRECAUTIONS

(7) Part No. 5450 929 1000

WARNING HOT SURFACES DO NOT TOUCH

(9) Part No. 5450 804 1000

DO NOT REMOVE RADIATOR CAP WHILE COOLANT IS HOT. WHEN COOL, ROTATE CAP SLOWLY TO THE FIRST STOP TO ALLOW EXCESS PRESSURE TO ESCAPE. THEN REMOVE CAP COMPLETELY.

TO AVOID PERSONAL INJURY :

WARNING

(10) Part No. G3907-88231

(11) Part No. 5450 801 1000

TO AVOID SERIOUS INJ URY OR DEATH:

(1) TURN OFF GENERATOR CIRCUIT BREAKER. (2) TURN OFF ALL SWITCHES ON ELECTRICAL LOAD. (3) MAKE CERTAIN LOAD CONNECTIONS AND POWER CABLES ARE IN GOOD CONDITION.

TO AVOID PERSONAL INJURY OR EQUIPMENT DAMAGE BEFORE STARTING ENGINE :

DO NOT OPERATE OR IDLE IN NONVENTILATED AREAS, CARBON MONOXIDE GAS IS COLORLESS, ODORLESS AND DEADLY.

DO NOT OPERATE IN WET OR DAMP CONDITIONS.

WARNINGDA NGER

(8) Part No. 5450 798 4000

WARNING HOT EXHAUST

(12) Part No. 5450 968 1000

TO AVOID PERSONAL INJURY

REAR COVER TERMINAL BLOCK2

2

1

1

WARNING WORK MUST BE CONDUCTED BY CERTIFIED PEOPLE. FIRST, STOP THE ENGINE AND REMOVE STARTER KEY. REMOVE THE NEGATIVE TERMINAL OF BATTERY AND CONDUCT THE WORK TO AVOID AUTOMATIC STARTING BY THE SYSTEM.

ADVICE OF INSPECTION AND CLEANING - TO PREVENT A TR ACKING FAILURE.

IN DUSTY CONDITIONS, FOREIGN MATTER CAN ACCUMULATE ACROSS THE TERMINAL BLOCK (2) OF THE GENERATOR.

HEN, WHEN IT GETS WET, ELECTRIC ARCING CAN OCCUR BETWEEN AIN TERMINALS AND IT CAUSES A SHORT CIRCUIT OF MAIN TERMINALS.

TO PREVENT THE FAILURE, REMOVE THE REAR COVER (1), AND CHECK FOR THE DUST AND MOISTURE ON THE TERMINAL BLOCK REGULARLY. (CLEAN WITH APPROVED CLEANING AGENT OR MOISTURE DISPLACER.) IN CASE ANY DISCOLORATION AND DEFORMATION OF THE TERMINAL BLOCK, REPLACE WITH NEW TERMINAL BLOCK.

(13) Part No. 1H773-88911 (EDL7000) (13) Part No. 1H774-88911 (EDL11000)

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7 SAFETY PRECAUTIONS

(15) Part No. 6C040-55591

(16) Part No. G3907-88311 (17) Part No. G3102-88371

(18) Part No. 5450 802 1000

MAY RESULT IF FINGERS OR CLOTHING ARE CAUGHT IN ROTATING PARTS. DO NOT OPERATE THE MACHINE WITH THE SIDE COVERS OR ACCESS DOORS REMOVED OR OPEN.

TO AVOID PERSONAL INJURY :

WARNING

(19) Part No. 18901-50632

(20) Part No. 18961-51351 (21) Part No. 18901-51352

(14) Part No. G3907-88331

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8SAFETY PRECAUTIONS

1

2

3 4 5 6 7

890q

w e

y u i o

pa

CARE OF DANGER AND WARNING LABELS 1. Keep danger and warning labels clean and free from obstructing material. 2. Clean danger and warning labels with soap and water, dry with a soft cloth. 3. Replace damaged or missing danger and warning labels with new labels from a Yamaha

dealer. 4. If a component with danger and warning label(s) affixed is replaced with new part, make sure

new label(s) is (are) attached in the same location(s) as the replaced component. 5. Mount new danger and warning labels by applying on a clean dry surface and pressing any

bubbles to outside edge.

r

t

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9 SERVICING OF GENERATOR

SERVICING OF GENERATOR Your dealer is interested in your new generator and has the desire to help you get the most value from it. After reading this manual thoroughly, you will find that you can do some of the regular maintenance yourself. However, when in need of parts or major service, be sure to see a Yamaha dealer. For service, contact the Yamaha dealership from which you purchased your generator or a Yamaha dealer.

When in need of parts, be prepared to give your dealer the generator and engine serial numbers. Locate the serial numbers now and record them in the space provided below.

model Serial No.

Generator

Engine

Date of Purchase

Name of Dealer

(To be filled in by purchaser)

(1) Generator serial number (2) Generator model (3) Engine serial number

1

2

2

1

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10SPECIFICATION

SPECIFICATION Model EDL7000SDE EDL11000SDE

Generator

Frequency 60 Hz

Rated output 6.5 kW 10.0 kW

Maximum output 7.0 kW 11.0 kW

Rated voltage 120 / 240 V

Rated current 54.2 / 27.1 A 83.3 / 41.7 A

Phase and wire 14 13

Number of poles 2

Power factor 1

Insulation Stator coil: B Rotor coil: F

Engine

Design Vertical, liquid cooled, 4 cycle, diesel

Model name Z482 D722

Rated output 8.1 kW 12.2 kW

Speed 3600 min-1 (rpm)

Number of cylinder - Bore Stroke 2- 67 68 mm (2 - 2.64 2.68 in.) 3- 67 68 mm (3 - 2.64 2.68 in.)

Displacement 0.479 L (29.23 cu.in.) 0.719 L (43.87 cu.in.)

Fuel tank capacity 28 L (7.4 U.S.gals)

Crankcase oil capacity 2.2 L (0.58 U.S.gals) 3.4 L (0.90 U.S.gals)

Starting system Electric type 12 V / 0.8 kW Electric type 12 V / 1.0 kW

Battery 38B20R 12 V 28 Ah / 5 Hr 55B24R 12 V 36 Ah / 5 Hr

Continuous operating hours (at rated load) 10 hrs 7 hrs

Net weight kg (lbs) 235 kg (518 lbs) 295 kg (650 lbs)

Output Receptacle

L14-30R L6-30R L5-30R

5-20RA (GFCI)

CS6369 (50A) L6-30R L5-30R

5-20R (GFCI) 2

*Conversion Formula: HP=0.746 kW, PS=0.7355 kW

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11 NOMENCLATURE

NOMENCLATURE

(1) Door (2) Coolant filling port (3) Hook (4) Fuel tank cap (5) Fuel gauge (6) Control panel (7) Base (8) Engine oil drain plug (9) Door lock (10) Coolant drain plug (11) Reserve tank (12) Fuel filter (13) Oil dipstick

(14) Oil filter cartridge (15) Muffler (16) Radiator (17) Radiator cap (18) Solenoid (19) Engine oil port (20) Battery (21) Air cleaner (22) Door stopper (23) Fuel tank (24) Alternator (25) Safety shield

dfg

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12NOMENCLATURE

Control Panel Standard Model 1 Phase Type (120/240 V Dual voltage Type)

[EDL11000SDE]

1

2

A BCD

3 45q

8

6

9

7

0

[EDL7000SDE]

1 3 45q

2

8

6

9 A

B

C

D

7

0

w

(1) A.C. Voltmeter (2) Glow timer lamp (3) Water temperature lamp (4) Oil pressure lamp (5) Battery charge lamp (6) Starter switch (key) (7) Circuit breaker (8) Hour meter (9) Ground terminal (10) Protector (Receptacle) (11) Pilot lamp (12) Full power switch

(A) Receptacle (B) Receptacle (C) Receptacle (D) Receptacle

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13 GROUND FAULT CIRCUIT INTERRUPTER (GFCI) RECEPTACLE

GROUND FAULT CIRCUIT INTERRUPTER (GFCI) RECEPTACLE WARNING

(1) Do not operate in wet or damp conditions.

(2) This Ground Fault Circuit Interrupter reduces the hazards of ground fault currents that can cause loss of life.

(3) The GFCI will not protect against short circuits or over loads.

(4) Do not use the GFCI or other standard receptacles on the circuit until the GFCI has been fully and successfully tested.

See following test procedure.

TESTING PROCEDURE (1) Unplug all appliances from the GFCI receptacle. (2) Start the engine. (3) At the circuit breaker turn power ON to the circuit. (4) Depress the TEST button. The RESET button should extend with a click. If the RESET button does not extend, contact a

Yamaha dealer. (5) Depress the RESET button firmly into the GFCI

unit, until an audible click is heard. If it resets properly, the RESET button will be

flush with the surface of the TEST button. If the RESET button is not flush with TEST

button, contact a Yamaha dealer.

When the RESET Button Extends During Operation:

(1) Unplug all appliances from the GFCI receptacle. (2) Depress the RESET button firmly into the GFCI

unit, until an audible click is heard. If the GFCI can not be reset, the GFCI is faulty. Contact a Yamaha dealer. If the GFCI resets

properly, check such things as fault insulation or wet wiring inside the appliance or its cord. If youve found the short, it should be repaired before it is used again.

1. Perform this test on a regular monthly basis to ensure proper operation of the GFCI receptacle.

2. If the generator is stored outdoors, unprotected from the weather, test the GFCI receptacle before each use.

3. An attached OCCUPANTS TEST RECORD label should be retained and placed in a conspicuous location to remind the operator that for maximum protection against electrical shock.

4. Record your test on the GFCI test card.

5. After disassembling and assembling the generator, check the circuit of GFCI with the RECEPTACLE CIRCUIT TESTER and test as above TEST PROCEDURE.

(1) TEST button (2) RESET button

Easy Checker When an abnormal condition occurs with a part monitored by the easy checker while the engine is running, a lamp flashes to warn the operator of the impending trouble.

(1) Charge warning lamp (2) Water temperature-overheat warning lamp, flashes on

when cooling water rises to 112 to 118C. (3) Engine oil pressure drop warning lamp, flashes on below

68.7 to 127.5 kPa (0.7 to 1.3 kgf/cm2) oil pressure. (4) Glow timer lamp

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14GROUND FAULT CIRCUIT INTERRUPTER (GFCI) RECEPTACLE

Control Box

EDL7000SDE

EDL11000SDE

(1) Emergency unit (2) Regulator (3) Glow relay (4) Relay A (5) Relay B (6) Glow lamp timer (7) Starter relay (8) Exterior connection terminal taps (9) Separate excitation unit

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15 PREPARATION TO SUPPLY THE ELECTRIC POWER

PREPARATION TO SUPPLY THE ELECTRIC POWER Generator Grounding

The end user, equipment owner or operator must contact his local, state, county or municipal electric code department to determine the approved generator grounding method to be used in his application or location. Recommendations in the NEC (National Electrical Code), NFPA (National Fire Protection Association), AUSTRALIAN STANDARDS and OSHA (Occupational Safety and Health Administration) regulations must be followed to assure compliance and safe operation. Always be sure to ground (earth) the generator terminals to comply with the local, state, national or OSHA requirements.

One possible connection method for construction site use is as follows:

(1) Generator ground terminal (A) #6AWG Flexible copper ground

connection (B) Metal ground rod or

building cold water pipe system per N.E.C. code

Recommended Capacity of Electrical Devices

Application range You can operate the EDL-series generator in the following range.

Typical Apparatus Light and

heaters Commutator

motor Induction

motor

EDL7000SDE 6.5 kW 3.3 kW 0.8 kW

EDL11000SDE 10 kW 5.0 kW 1.6 kW

TIP 8 Keep an inverter load below 50% of the generator

capacity. 8 Make sure that total active mercury lamp load is

below 30% or so of the generator capacity. Turn on the mercury lamps one by one. Be careful not to turn off the lamps and on again immediately. The generator voltage may rise to extremely high levels and the AVR may get damaged.

8 Before turning on the lamps again, wait for 10 minutes or so until the lamps cool down enough.

8 The data shown above is only a guideline to approximate load capacities and may vary from generator model to generator model, with different types of loads at rated outputs. These values may be different from actual applications because of the input characteristics peculiar to each load.

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16PREPARATION TO SUPPLY THE ELECTRIC POWER

8 Connecting a motor. When starting the motor, the voltage drops

immediately. The circuit may be opened if an electromagnetic switch is connected to the same circuit. When connecting two motors or more, make sure the total current capacity of the motors does not exceed the total rated current.

8 Connecting to lights and electric heaters. When connecting to lights or electric heaters, the

generator can be used up to the rated capacity. When using a single phase, it can be used up to

the rated current. 8 Power factor calculations. The power factor calculation is used to determine

input of the electrical devices.

AC devices Electric power (W) = Voltage (V) Current (A) Power factor

Power factors of commonly used devices are listed in the following table.

Load type Power factor

Single-phase induction motors 0.4 to 0.75

Electric heaters, incandescent lamps 1.0

Commutator motor 0.8 to 0.95

Fluorescent lamps, mercury lamps 0.4 to 0.9

AC arc welder 0.4 to 0.6

8Ordinarily, a motor is rated in kW. This does not refer to motor output.

Motor input (kVA)

Motor output (kW) = Motor efficiency power factor

TIP 8 If a lighting system is employed together with some

types of computers and inverter air-conditioners and/or the regulated power supply for TV sets, the lights might suffer flickering. This phenomenon does not indicate a fault of the generator: it is caused by poor matching between the above- mentioned regulated power supply and the generators automatic voltage regulator. In such a case, modify the load combination to eliminate the flickering.

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17 CONNECTING THE LOAD

CONNECTING THE LOAD Connection Notes

WARNING To avoid personal injury: 8 Before the generator can be

connected to a buildings electrical system, a licensed electrician must install an isolation (transfer) switch in the buildings main fuse box. The switch is the connection point for generator power and allows selection of generator or main line power to the building. This will prevent the generator from charging the main power line (backfeeding) when the main power supply has failed or has been turned off for line repair. Backfeeding can electrocute or injure line maintenance personnel. Also, generator and building electrical system damage can occur when normal operating power returns if unit is used without an isolation switch.

1. Avoid connecting the generator to commercial power outlet.

2. Avoid connecting the generator in parallel with any other generator.

Connecting the Load (Receptacles Output Model)

WARNING To avoid personal injury: 8 Connect or disconnect the load

to the AC receptacle only when the engine is stopped.

i) EDL11000SDE 60 Hz 120/240 V ii) EDL7000SDE 60 Hz 120/240 V

1. Turn OFF the circuit breaker on the control panel.

1

A

B

C

D

1

A

C

D

B

(1) Circuit breaker (A) Receptacle (B) Receptacle (C) Receptacle (D) Receptacle

2. Connect the load to the A.C. receptacles.

i)

ii)

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18PRE-OPERATION CHECK

PRE-OPERATION CHECK How to Open the Door

WARNING To avoid personal injury from contact with moving parts: 8 DO NOT open the door or

generator side cover while the engine is running.

8 Do not touch muffler or exhaust pipes while they are hot; Severe burns could result.

(1) Door stopper

Daily Check To prevent problems from occurring, it is important to know the condition of the generator. Always perform the following check items before starting the generator.

WARNING To avoid personal injury: 8 Before checking or servicing

the generator, make sure it is on a level surface with the engine shut off.

Check items - Check for oil and coolant leakage - Check cooling air inlet and outlet for obstructions or

clogging - Check radiator fins for clogging - Check fan belt tension - Check engine oil level - Check coolant level - Check generator grounding - Refuel (See Fuel in PERIODIC SERVICE section.) - Care of danger and warning labels (See DANGER AND WARNING LABELS in

SAFETY PRECAUTIONS section.)

WARNING To avoid personal injury from contact with moving parts: 8 DO NOT open the door or

generator side cover while the engine is running. 8 Do not touch muffler or exhaust

pipes while they are hot; Severe burns could result.

Battery The battery is shipped in dry, charged condition without electrolyte. The battery must be charged properly before using for the first time.

DANGER To avoid the possibility of battery explosion:

The battery comes in two types: refillable and non-refillable. For using the refillable type battery, follow the instructions below. 8 DO NOT use or charge the battery

if the fluid level is below the LOWER (lower limit level) mark.

Otherwise, the battery component parts may deteriorate prematurely, shorten the batterys service life; which may cause an explosion.

Immediately, add distilled water until the batterys fluid level comes somewhere between the UPPER and LOWER levels.

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19 PRE-OPERATION CHECK

8 Keep all sparks and flames away from the battery and fuel tank. A battery, especially when charging, will give off hydrogen and oxygen gases which can explode and cause serious personal injury.

1. Remove the vent plugs. 2. Fill cells up to the upper level with electrolyte. [Specific gravity of sulfuric acid 1.270 to 1.290 (at

20C = 68F)] 3. Allow the battery to sit for about one hour after

filling. 4. If the electrolyte level is dropped, refill with

electrolyte up to the upper level. 5. Replace the vent plugs. 6. Charge the battery at the normal charging rate of

6.0 amperes. 7. Wash off any electrolyte which may have spilled.

(1) Vent plug opening (2) Electrolyte level indication

tube (3) Indicated level

(A) Upper level (B) Lower level

TIP 8 The duration of dry charged efficiency, will decrease

in proportion to the period of time elapsed after shipment and during storage. To obtain the longest service life of the battery, it is necessary for the battery to be charged for a sufficient period of time. Continue to charge until all cells are gassing freely, and the voltage and specific gravity reading in all cells remain constant for 3 or more successive readings taken at 30 minute intervals.

8 When the battery has been charged fully, the specific gravity of electrolyte should be 1.270 to 1.290 (at 20C = 68F).

Engine oil The generator has been shipped without engine oil. Fill with oil to the correct level before attempting to start the engine.

1. Place the machine on a level surface. 2. Remove the oil cap. 3. Add engine oil of grade CD or higher, up to the

upper mark on the oil level gauge.

TIP 8 See Engine Oil in PERIODIC SERVICE section

for engine oil capacity and checking engine oil level.

Coolant

WARNING To avoid personal injury: 8 Place the machine on a level

surface. 8 DO NOT remove the radiator

cap while coolant is hot. When cool, rotate the radiator cap slowly to the first stop to allow excess pressure to escape. Then remove cap completely.

1. Remove the radiator cap and fill with specified coolant until the coolant level is just below the port.

2. Fill with coolant to the FULL mark on the reserve tank.

3. Securely tighten radiator cap and reserve tank cap.

TIP 8 See Radiator in PERIODIC SERVICE section

for changing coolant.

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20PRE-OPERATION CHECK

Fuel

WARNING To avoid personal injury: 8 DO NOT refuel when engine is

running or hot. 8 Always shut off the engine

before refueling. 8 DO NOT overfill fuel system.

If any fuel overflows, wipe it up completely before starting operation.

8 When refueling, keep all flames, sparks and cigarettes away from generator.

1. Always fill the fuel through the fuel tank strainer. 2. Make sure that dirt or water does not enter the fuel

tank. 3. Fill with Diesel fuel No.2-D (ASTMD975). 4. Below 0C (32F) a mix of No.1-D and No.2-D is

acceptable. 5. Fuel level is read by fuel gauge.

TIP 8 If the fuel tank should empty completely causing

the engine to stop, then the fuel system requires air bleeding after filling the tank and before restarting the engine.

(See Air bleeding the fuel system in PERIODIC SERVICE section.)

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21 OPERATING THE GENERATOR

OPERATING THE GENERATOR WARNING

To avoid personal injury: 8 Read SAFETY PRECAUTIONS

in the front of this manual. 8 Read the danger and warning

labels located on the generator. 8 To avoid the danger of exhaust

fume poisoning, do not operate the engine in a closed building without proper ventilation. 8 Always turn OFF the circuit

breaker before starting the generator. 8 Turn OFF all switches on the

electrical devices. 8 Check the wiring and

connections of the electrical devices before starting the machine. 8 DO NOT touch the live parts

during operation.

Starting the Engine 1. Turn OFF all switches on the electrical

devices. 2. Turn OFF the circuit breaker on the

control panel.

1

A

(1) Circuit breaker (A) OFF

3. Ensure that the fuel filter cock is set to the OPEN position.

(1) Fuel filter cock (2) Fuel filter pot

(A) OPEN

4. Insert the key into the starter switch and turn it ON.

5. Check the battery charge lamp and oil pressure lamp are ON.

(1) Water temperature lamp (2) Oil pressure lamp (3) Battery charge lamp (4) Glow timer lamp

NOTICE 8 Do not use ether or any starting

fluid for starting the engine, or severe engine damage will occur.

6. Turn the starter switch (key) to PREHEAT position.

TIP 8 See Cold Weather Starting section as to the

preheating times.

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22OPERATING THE GENERATOR

7. Turn the starter switch (key) to the START position and release when the engine starts.

(1) Starter switch (key) (A) OFF (B) ON (C) PREHEAT (D) START

NOTICE 8 Do not run the starter motor

continuously for more than 10 seconds at a time, or it may damage the starter. If the engine fails to start, wait for about 30 seconds and try again.

8. Check to see that the battery charge lamp, oil pressure lamp and water temperature lamp are OFF.

9. Check the warning lamps. Whenever the engine stops automatically during

operation, correct the problem before restarting the engine.

NOTICE 8 Be sure to warm up the

engine, not only in winter, but also in warmer seasons. An insufficiently warmed-up engine can shorten its service life.

Warm-up in cold ambient temperatures In cold weather, the engine oil may be cold with increased viscosity. This can delay oil circulation or abnormally low oil pressure for some time after engine start-up. This can result trouble in the lubrication circuit or damage to the engine moving parts. To prevent the above problems, perform the following instructions: Warm up the engine at rated revolution with no load.

Ambient temperature Warm-up time requirement

Above 0C (32F) At least 10 minutes

0C (32F) to -10C (14F) 10 to 20 minutes

Below -10C (14F) More than 20 minutes

10. Turn ON the circuit breaker on the control panel.

1

A

(1) Circuit breaker (A) ON

NOTICE 8 When there is a severe overload

or short circuit in the wiring of the generator, the circuit breaker turns OFF. If this happens, eliminate the cause and then turn the circuit breaker ON again.

11. Turn ON the electrical device switches for the connections.

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23 OPERATING THE GENERATOR

Cold Weather Starting If the ambient temperature is below * -5C (23F) and the engine is very cold, start it in the following manner: Take steps (1) through (5) in Starting the Engine section.

6. Turn the starter switch (key) to the PREHEAT position until the glow plug indicator goes off.

TIP 8 If the ambient temperature is low, the preheating

time will take longer.

NOTICE 8 Shown below are the standard

preheating times for various temperatures. This operation, however, is not required, when the engine is warmed up.

Ambient temperature Preheating time

Above 10C (50F) NO NEED

10C (50F) to -5C (23F) Until glow lamp goes off

*Below -5C (23F) Approx. 5 seconds after the glow lamp goes off

Limit of continuous use 20 seconds

7. Turn the starter switch (key) to START position and the engine should start.

(If the engine fails to start after 10 seconds, turn off the starter switch (key) for 30 seconds. Then repeat steps (6) and (7) above.)

NOTICE 8 Do not allow the starter motor

to run continuously for more than 10 seconds. 8 Be sure to warm up the

engine, not only in winter, but also in warmer seasons. An insufficiently warmed-up engine can shorten its service life. 8 When there is possibility of

temperature drops below -15C (5F) detach the battery from the machine, and keep it indoor in a safe area. Reinstalled the battery before the next operation.

Stopping the Engine 1. Turn OFF all electrical device switches

for connected loads.

2. Turn OFF the circuit breaker.

3. Allow the engine to run with no load for about 5 minutes before stopping the engine completely.

4. Turn the starter switch (key) to the OFF position.

(1) Starter switch (key) (A) OFF (B) ON (C) PREHEAT (D) START

5. Turn the fuel filter cock to the CLOSE position.

(1) Fuel filter cock (2) Fuel filter pot

(A) CLOSE

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24OPERATING THE GENERATOR

If the Engine Fails to Stop in the Usual Procedure (EMERGENCY STOP)

If the engine does not stop after turning the starter switch (key) to OFF position, take the following (EMERGENCY STOP) procedure.

WARNING To avoid personal injury: 8 Keep your hands away from the

rotating parts, such as cooling fan and V-belt. Otherwise personal injury may be caused when manipulating the engine stop lever.

1. Open the door, using the door knob. 2. Turn the engine stop lever to STOP direction and

hold it for 5 to 10 seconds to shut off the engine.

(1) Engine stop lever (A) START (B) STOP

3. After stopping the engine, make sure that the door is closed and the starter switch (key) is at OFF.

4. The following causes are possible for such unusual engine shut-off.

Pinpoint and correct the cause of trouble. 8 Check for the stop solenoid. 8 Check to see if the battery has discharged too

much or is in trouble. 8 Check for disconnection of the battery

terminals.

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25 SERVICE INTERVALS

SERVICE INTERVALS Observe the following for service and maintenance. The lubricating oil change intervals listed in the table below are for Classes CF, CE and CD lubricating oils of API classification with a low-sulfur fuel in use. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur fuel, change the lubricating oil at shorter intervals than recommended in the table below depending on the operating condition.

No. Check point

Interval Ref. page

First 50

hours

Every 50

hours

Every 100

hours

Every 200

hours

Every 400

hours

Every 500

hours

Every 800

hours

Every 1500 hours

Every 3000 hours

Every 1

year

Every 2

years

1 Check of fuel pipes and clamp bands 4 28 @

2 Change of engine oil 5 4 30 5

3 Cleaning of air cleaner element 4 31 *1 @

4 Check of battery electrolyte level 5 4 35

5 Check of fan belt tension 4 38

6 Check of radiator hoses and clamp bands 4 34

7 Check of intake air hose 4 @

8 Replacement of oil filter cartridge 5 4 30 5

9 Replacement of fuel filter cartridge or element 4 @

10 Cleaning of fuel filter 4 29

11 Cleaning of water jacket (radiator interior) 4 34

12 Replacement of fan belt 4 38

13 Check of valve clearance 4

14 Replacement of air cleaner element 4 31 *2 @

15 Check of damage in electric wiring and loose connections 4 37

16 Check of fuel injection nozzle injection pressure 4 *3 @

17 Check of injection pump 4 *3 @

18 Replacement of fuel pipes, fuel gauge and clamp bands 4 28 *3 @

19 Replacement of radiator hoses and clamp bands 4 34

20 Replacement of battery 4 35

21 Change of radiator coolant (L.L.C.) 4 33

22 Replacement of intake air hose 4 *4 @

NOTICE 8 The jobs indicated by 5 must be done after the first 50 hours of operation. *1 Air cleaner should be cleaned more often in dusty conditions than in normal conditions. *2 After 6 times of cleaning. *3 Consult a Yamaha dealer for this service. *4 Replace earlier if necessary. 8 The items listed above (@ marked) are registered as emission related critical

parts by Yamaha in the U.S. EPA non-road emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according to the above instruction.

Please see the Warranty Statement in detail. 8 When the battery is used for less than 100 hours in a year, check its electrolyte

yearly. (for refillable batterys only)

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26SERVICE INTERVALS

TIP Engine Oil: 8 Oil used in the engine should have an American Petroleum Institute (API) service classification and Proper

SAE Engine Oil according to the ambient temperatures as shown P30.

8 Refer to the following table for the suitable API classification engine oil according to and the fuel.

Fuel used Engine oil classification (API classification)

Ultra Low Sulfur Fuel [<0.0015% (15 ppm)] CF, CF-4, CG-4, CH-4 or CI-4

8 The CJ-4 engine oil is intended for DPF (Diesel Particulate Filter) type engines.

Fuel: 8 Cetane number of 45 minimum. Cetane number greater than 50 is preferred, especially for temperatures

below -20C (-4F) or elevations above 1500 m (5000 ft). 8 Diesel fuels specified to EN 590 or ASTM D975 are recommended. 8 No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313

JUN87) 8 Since this engine adopts EPA Tier 4 and Interim Tier 4 standards, the use of ultra low sulfur fuel is mandatory

in EPA regulated area (North America). Therefore, please use No.2-D S15 diesel fuel as an alternative to No.2-D, or use No.1-D S15 diesel fuel as an alternative to No.1-D if outside air temperature is below -10C (14F).

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27 PERIODIC SERVICE

PERIODIC SERVICE Fuel

Fuel is flammable and can be dangerous. You should handle fuel with care.

WARNING To avoid personal injury: 8 DO NOT mix gasoline or alcohol

with diesel fuel. This mixture can cause an explosion. 8 Be careful not to spill fuel

during refueling. If fuel should spill, wipe it off at once, or it may cause a fire. 8 Stop the engine before

refueling. Keep the machine away from fire. 8 Be sure to stop the engine while

refueling or bleeding and when cleaning or changing fuel filter or fuel pipes. DO NOT smoke when working around the machine or when refueling. 8 Check the above fuel systems

in a well ventilated and open place. 8 When fuel and lubricant are

spilled, refuel after the machine cooled down.

Fuel level check and refueling 1. Check to see that the fuel level is above the lower

limit of the fuel level gauge. 2. If the fuel is too low, add fuel to the upper limit. Do

not overfill.

(1) Fuel level gauge

No.2-D is a distillate fuel oil of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87) Grade of Diesel Fuel Oil According to ASTM D975

Flash Point, C

(F)

Water and Sediment, volume %

Carbon Residue on, 10 percent

Residuum, %

Ash, weight %

Min Max Max Max

52 (125) 0.05 0.35 0.01

Distillation Tempera-

tures, C(F) 90% Point

Viscosity Kinematic

cSt or mm2/s at 40C

Viscosity Sayboit,

SUS at 100F

Sulfur, weight

%

Copper strip

Corro- sion

Cetane Num- ber

Min Max Min Max Min Max Max Max Min

282 (540)

338 (640)

1.9 4.1 32.6 40.1 0.50 No.3 40

The cetane number is required not to be less than 45.

NOTICE 8 Be sure to use a strainer when

filling the fuel tank, or dirt or sand in the fuel may cause trouble in the fuel injection pump. 8 Always use diesel fuel.

You are required not to use alternative fuel, because its quality is unknown and affect the generator performance. Kerosene, which is very low in cetane rating, adversely affects the engine. Diesel fuel differs in grades depending on the temperature. 8 Be careful not to let the fuel tank

become empty, or air can enter the fuel system, necessitating bleeding before next engine start.

Fuel tank capacity L (U.S.gal.)

Model Capacity

EDL7000SDE [Engine model : Z482]

EDL11000SDE [Engine model : D722]

28 (7.4)

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28PERIODIC SERVICE

Air bleeding the fuel system

WARNING To avoid personal injury: 8 Do not bleed a hot engine as

this could cause fuel to spill onto a hot exhaust manifold creating a danger of fire.

Air bleeding of the fuel system is required if; 8 After the fuel filter and pipes have been detached

and refitted; 8 After the fuel tank has become empty; or 8 Before the engine is to be used after long storage.

[PROCEDURE] 1. Fill the fuel tank to the fullest extent. Open the fuel

filter cock. 2. Loosen air vent plug of the fuel filter a few turns. 3. Screw back the plug when bubbles do not come up

any more. 4. Open the air vent plug on top of the fuel injection

pump. 5. Retighten the plug when bubbles do not come up

any more.

(1) Fuel filter cock (2) Air vent plug (3) Fuel filter pot

(A) OPEN (B) CLOSE

Checking the fuel pipes

WARNING To avoid personal injury: 8 Check or replace the fuel pipes

after stopping the engine. Broken fuel pipes can cause fires.

Check the fuel pipes every 50 hours of operation. When if; 1. If the clamp band is loose, apply oil to the screw of

the band, and tighten the band securely. 2. If the fuel pipes made of rubber became worn out

replace them and clamp bands every two years. 3. If the fuel pipes and clamp bands are found worn

or damaged before two years time, replace or repair them at once.

4. After replacement of the pipes and bands, air- bleed the fuel system.

NOTICE 8 When the fuel pipes are not

installed, plug them at both ends with clean cloth or paper to prevent dirt from entering. Dirt in the pipes can cause fuel injection pump malfunction.

(1) Clamp band (2) Fuel pipe

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29 PERIODIC SERVICE

Cleaning the fuel filter pot Every 100 hours of operation, clean the fuel filter in a clean place to prevent dust intrusion.

1. Close the fuel filter cock.

(1) Fuel filter cock (2) Fuel filter pot

(A) CLOSE (B) OPEN

2. Remove the top cap, and rinse the inside with diesel fuel.

3. Take out the element, and rinse it with diesel fuel. 4. After cleaning, reinstall the fuel filter, keeping out

of dust and dirt. 5. Air-bleed the injection pump.

NOTICE 8 Entrance of dust and dirt can

cause a malfunction of the fuel injection pump and the injection nozzle. Wash the fuel filter pot periodically.

Engine Oil

WARNING To avoid personal injury: 8 Be sure to stop the engine

before checking and changing the engine oil and the oil filter cartridge. 8 DO NOT touch muffler or exhaust

pipes while they are hot; severe burns could result. Always stop the engine and allow it to cool before conducting inspections, maintenance, or cleaning. 8 Contact with engine oil can

damage your skin. Put on gloves when handling

engine oil. If you come in contact with engine oil, wash it off immediately.

TIP 8 Be sure to check the engine oil on a level surface.

If placed on gradients, oil quantity can not be measured accurately.

NOTICE 8 Do not operate a diesel engine

when engine oil is overfilled. This can effect the air intake system which could result in engine damage or malfunction.

Checking oil level and adding engine oil 1. Check the engine oil level before starting or more

than 5 minutes after stopping the engine. 2. Remove the oil level gauge, wipe it clean and

reinstall it. 3. Take the oil level gauge out again, and check the

oil level.

(1) Oil port (2) Oil level gauge

[Lower end of oil level gauge] (A) Engine oil level within this

range is proper.

4. If the oil level is too low, remove the oil port, and add new oil to the prescribed level.

5. After adding oil, wait more than 5 minutes and check the oil level again. It takes some time for the oil to drain down to the oil pan.

6. If the engine is operated with the oil level nearing the lower limit, the oil may deteriorate more quickly than normal, therefore, keeping the oil level near the upper limit is recommended.

Engine oil capacity L (U.S.qts.)

Model Capacity

EDL7000SDE [Engine model : Z482] 2.2 (2.3)

EDL11000SDE [Engine model : D722] 3.4 (3.6)

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30PERIODIC SERVICE

NOTICE 8 Engine oil should be MIL-L-

2104C or have properties of API classification CD grades or higher. Change the type of engine oil according to the ambient temperature.

above 25C (77F) SAE30 or SAE10W-30 SAE10W-40

0 to 25C (32 to 77F) SAE20 or SAE10W-30 SAE10W-40

below 0C (32F) SAE10W or SAE10W-30 SAE10W-40

8 When using oil of different brands from the previous one, be sure to drain all the previous oil before adding the new engine oil.

Changing engine oil

WARNING To avoid personal injury: 8 Be sure to stop the engine

before draining engine oil. 8 When draining engine oil, place

a suitable container underneath the engine and dispose of it according to local regulations.

8 DO NOT drain oil from a hot engine. Allow engine to cool down sufficiently to avoid being burned.

1. Change oil after the initial 50 hours of operation and every 100 hours thereafter.

2. Remove the drain plug to drain the engine oil. Drain all the old oil, drains easier and completely when the engine is warm. Inspect drain plug gasket. Replace if damaged.

(1) Engine oil drain plug

3. Install the oil drain plug and gasket. 4. Add new engine oil up to the upper line of the oil

level gauge.

Replacing the oil filter cartridge

WARNING To avoid personal injury: 8 Be sure to stop the engine

before changing the oil filter cartridge. 8 Allow engine to cool down

sufficiently. Oil can be hot and cause burns.

1. Replace the oil filter cartridge every 200 hours of operation.

2. Remove the old oil filter cartridge with a filter wrench. Dispose of filter properly.

3. Apply a film of oil to the gasket of the new cartridge. 4. Screw in the cartridge by hand. When the gasket

contacts the seal surface, tighten the cartridge firmly only by hand. If you tighten the cartridge with a wrench, it will be tightened too much.

(1) Oil filter cartridge (2) Remove with a filter wrench (Tighten with your hand)

5. After the new cartridge has been replaced, the engine oil level normally decreases a little. Therefore run the engine for a while and check for oil leaks through the seal before checking the engine oil level. Add oil if necessary.

TIP 8 Completely wipe off any oil sticking to the machine

in the filter area.

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31 PERIODIC SERVICE

Air Cleaner

WARNING To avoid personal injury: 8 Be sure to stop the engine

before cleaning air filter element.

NOTICE 8 Make sure hooking clip is tight

enough. If it is loose, dust and dirt may be sucked into the engine, causing excessive wear or premature engine failure and need for engine repair.

Cleaning secondary air filter element Since the air cleaner employed on this engine is a dry type, never apply oil to it. 1. Open the evacuator valve once a week under

ordinary conditions - or daily when used in severe or dusty conditions. This will get rid of large particles of dust and dirt.

2. Wipe the inside air cleaner clean with cloth if it is dirty or wet.

3. Avoid touching the element except when cleaning. 4. When dry dust adheres to the element, blow

compressed air from the inside turning the element. Pressure of compressed air must be under 205 kPa (2.1 kgf/cm2, 30 psi).

5. When carbon or oil adheres to the element, soak the element in detergent for 15 minutes, then wash it several times in water, rinse with clean water and dry it naturally.

6. After the element is fully dried, inspect the inside of the element with a light, and check if it is damaged or not. (referring to the instructions on the label attached to the element.)

7. Replace the primary element every year or every 6 cleanings. If the primary element is heavily stained, replace it sooner. At this time, also replace the secondary element.

8. The secondary element should be removed only if it is to be replaced.

9. To protect the engine, do not remove the secondary element in normal servicing of the primary element.

(1) Air cleaner

(1) Air cleaner body (2) Cover (3) Secondary element (4) Primary element (5) Evacuator valve (6) Hooking clip

Cleaning primary air filter element 1. To clean the element, use clean dry compressed

air on the inside of the element. Air pressure at the nozzle must not exceed 205

kPa (2.1 kgf/cm2, 30 psi). Maintain reasonable distance between the nozzle

and filter. 2. To wash the elements, use Donaldson ND-1500

Filter Cleaner, or its equivalent, which is especially effective on oily and soot-laden filters. Follow instructions that are supplied with the filter cleaner.

Evacuator valve Open the evacuator valve once a week under ordinary conditions - or daily when used in dusty condition - to get rid of large particles of dust and dirt.

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32PERIODIC SERVICE

NOTICE 8 If the dust cup is mounted

incorrectly, dust or dirt will not collect in the cup and allow the dust to come into direct contact with the element and thus require the element be replaced prematurely.

(1) Air cleaner body (2) Secondary element (3) Primary element (4) Dust cup (5) TOP mark (6) Evacuator valve

Air cleaner with dust cup Remove and clean out the dust cup once a week under normal conditions or daily in extreme conditions. Do not allow the dust cup to fill above half way regard- less of conditions. Install the air cleaner dust cup with TOP indicated on the rear of the cup in the upward position with horizon- tally mounted air cleaner bodies or vertically mounted air cleaner bodies, the cup may be mounted in any direction.

Radiator Make it a rule to check the coolant level before every operation.

WARNING To avoid personal injury: 8 DO NOT stop the engine

suddenly, stop it after about 5 minutes of unloaded idling. 8 Work only after letting the

engine and radiator cool off completely (more than 30 minutes after it has been stopped). 8 DO NOT remove the radiator cap

while coolant is hot. When cool, rotate cap slowly to the first stop to allow excess pressure to escape.

Then remove cap completely. If overheating should occur,

steam gushes out from the radiator or reserve tank; Allow the engine to cool before attempting to open the cap. Severe burns could result.

Checking coolant level, adding coolant 1. Remove the radiator cap after the engine has

completely cooled, and check to see that coolant reaches the supply port.

(1) Radiator cap (2) Coolant filling port

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33 PERIODIC SERVICE

2. If the radiator is provided with a reserve tank, check the coolant level of the reserve tank. When it is between the FULL and LOW marks, the coolant will usually last for one days work.

(1) Reserve tank (2) Cap

(A) FULL Upper line 0.6 L (0.63 U.S.qts.) (B) LOW

3. When the coolant level drops due to evaporation, add only 50/50 coolant up to the full level.

4. Check to see the two drain plug; one is at the crankcase side and the other is at the lower part of the radiator as shown below.

(1) Coolant drain plug (Radiator) (2) Radiator (3) Coolant drain plug (Engine)

NOTICE 8 If the radiator cap has to be

removed, proceed with caution and securely retighten the cap. 8 If coolant is leaking, consult a

Yamaha dealer. 8 Make sure that muddy or sea

water is not used in the radiator. 8 Use clean, fresh water and 50%

anti-freeze to fill the recovery tank.

8 Do not refill reserve tank with coolant over the FULL level mark. 8 Be sure to close the radiator

cap securely. If the cap is loose or improperly closed, coolant may leak out and decrease the level quickly. 8 When coolant is added, coolant

level may drop the first time the engine is started. Stop the engine, and add coolant if necessary.

Changing coolant 1. To drain coolant, always remove both drain plugs

and simultaneously open the radiator cap as well. With the radiator cap kept closed, the coolant will

not drain completely. Dispose of used coolant properly.

2. Remove the overflow pipe of the radiator pressure cap to drain the reserve tank.

3. Prescribed coolant volume L (U.S.qts.)

Model Capacity

EDL7000SDE [Engine model : Z482] 3.7 (3.9)

EDL11000SDE [Engine model : D722] 4.1 (4.3)

include reserve tank 0.6 L (0.63 U.S.qts.)

4. An improperly tightened radiator cap or a gap between the cap and the seat increases loss of coolant.

5. Coolant (Water and anti-freeze) All seasons: Pure water and anti-freeze (See Anti- freeze in Radiator section.)

Remedies for rapid coolant loss 1. Check for dust and dirt between the radiator fins

and cooling tube. Clean the fins and the tubes as if necessary.

2. Check the tension of the fan belt. If loose, tighten it securely.

3. Check the internal blockage in the radiator cooling tubes. If scale forms in the tubes, clean with the scale inhibitor or its equivalent.

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34PERIODIC SERVICE

Checking radiator hoses and clamps

WARNING To avoid personal injury: 8 Be sure to check radiator hoses

and hose clamps periodically. If radiator hoses are damaged or coolant leaks out, overheating can occur.

Check to see if radiator hoses are properly fixed every 200 hours of operation or 6 months, whichever comes first. 1. If hose clamps are loose or water leaks, tighten

hose clamps securely. 2. Replace hoses and hose clamps if radiator hoses

are swollen, hardened or cracked.

Replace hoses and hose clamps every 2 years, or earlier as required, if hoses are found to be swollen, hardened or cracked.

(1) Radiator hose (2) Hose clamp

Precaution at overheating The event that the coolant temperature is nearly or more than the boiling point is called OVERHEATING. While running, make the following checks to see that all parts are working correctly. If anything is unusual, inspect it, referring to the relevant description in SERVICE INTERVALS and PERIODIC SERVICEsection.

8 Coolant If the coolant temperature warning lamp lights up or if steam or coolant does not stop squirting from the radiator overflow pipe, turn off the load and keep the engine idling (COOLING-DOWN) for at least 5 minutes to let it cool down gradually. Then stop the engine and take the following inspection and servicing. 1. Check to see if the coolant runs short or if there is

any coolant leak; 2. Check to see if there is any obstacle around the

cooling air inlet or outlet; 3. Check to see if there is any dirt or dust between

radiator fins and tube; 4. Check to see if the fan belt is too loose; and 5. Check to see if radiator water pipe is clogged.

Cleaning radiator core (outside) If dust is between the fin and tube, wash it away with running water.

NOTICE 8 Do not clean radiator with

firm tools such as spatulas or screwdrivers. They may damage the delicate fins or tubes. It can cause coolant leaks or decrease cooling performance. 8 Be careful to keep water off of

electrical parts.

Cleaning the radiator Clean the cooling system of the engine every 500 hours. In addition, clean it before adding anti-freeze and before stopping use of anti-freeze.

Anti-freeze

WARNING To avoid personal injury: 8 When using anti-freeze, put on

some protection such as rubber gloves. 8 When anti-freeze comes in

contact with the skin or clothing, wash it off immediately. 8 DO NOT mix different types of

anti-freeze. 8 Keep fire and children away

from anti-freeze. 8 Be mindful of the environment

and ecology. Before draining any fluids, find out the correct way of disposing by checking with local codes. 8 Also, observe the relevant

environmental protection regulations when disposing of oil, fuel, coolant, filters and batteries.

If coolant freezes it can damage the cylinders and radiator. It is necessary, if the ambient temperature falls below 0C (32F), to either drain coolant after operating or to add anti-freeze to it. 1. There are two types of anti-freeze available; use

the permanent type (PT) for this engine. 2. Before adding anti-freeze for the first time, clean

the radiator and engine interior by pouring fresh water, and draining it a few times.

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35 PERIODIC SERVICE

3. The procedure for the mixing of water and anti- freeze differs according to the make of the anti- freeze and the ambient temperature. Follow the instructions on the container.

4. Mix the anti-freeze with water, and then pour into the radiator.

NOTICE 8 When the anti-freeze is mixed

with water, the anti-freeze mixing ratio must be less than 50%.

Vol % Anti-freeze

Freezing Point Boiling Point *

C F C F

40 50

-24 -37

-12 -34

106 108

222 226

* At 1.013 105 Pa (760 mmHg) pressure (atmospheric). A higher boiling point is obtained by using a radiator

pressure cap which permits the development of pressure within the cooling system.

TIP 8 The above data represents industry standards

that necessitate a minimum glycol content in the concentrated anti-freeze.

8 When the coolant level drops due to evaporation, add water only to keep the anti-freeze mixing ratio less than 50%. In case of leakage, add anti-freeze and water in the specified mixing ratio before pouring into the radiator.

8 Anti-freeze absorbs moisture. Keep unused anti- freeze in a tightly sealed container.

8 Do not use radiator cleaning agents when anti- freeze has been added to the coolant. (Anti-freeze contains an anti-corrosive agent, which will react with the radiator cleaning agent forming sludge which will affect the engine parts.)

Battery

WARNING To avoid personal injury: 8 Be careful not to let the battery

electrolyte contact your body or clothing.

8 Wear eye protection and rubber gloves, since the diluted sulfuric acid solution burns skin and eyes, and eats holes in clothing. Should this occur, immediately wash it off with running water and get medical attention.

Mishandling of the battery shortens the service life and adds to maintenance costs. Obtain the maximum performance and the longest life of the battery by handling properly and with care. Engine starting will be difficult, if the battery charge is low. Be sure to keep the battery in a fully charged state for best performance and battery life.

Battery charging

DANGER To avoid the possibility of battery explosion:

The batteries come in two types: refillable and non-refillable. For using the refillable type battery, follow the instructions below. 8 DO NOT use or charge the battery

if the fluid level is below the LOWER (lower limit level) mark.

Otherwise, the battery component parts may deteriorate prematurely, which will shorten the batterys service life or may cause an explosion.

Immediately, add distilled water until the batterys fluid level comes somewhere between the UPPER and LOWER levels. 8 When the battery is being

activated, hydrogen and oxygen gases in the battery are extremely explosive. Keep open sparks and flames away from the battery at all times, especially when charging the battery. 8 When charging the battery,

ensure the vent caps are securely in place (if equipped). 8 When disconnecting the cable

from the battery, start with the negative terminal, and when connecting them, start with the positive terminal first. 8 DO NOT check the battery charge

by placing a metal object across the terminals. Use a voltmeter or hydrometer.

9CN-9-10.indd 35 2012/05/25 15:59:08

36PERIODIC SERVICE

1. Make sure that each electrolyte level is to the bottom of vent wells, if necessary, add only distilled water in a well-ventilated place.

(1) Battery electrolyte level (A) TOO LOW (B) PROPER (C) TOO HIGH

2. To slow charge the battery, connect the charger positive terminal to the battery positive terminal, and the negative to the negative, then recharge in the normal manner.

3. Quick recharging charges the battery at a high rate in a short time. This is only for emergencies.

4. Recharge the battery as early as possible, or battery life will be extremely shortened.

5. When exchanging an old battery for a new one, use a battery of equal specifications shown in page 10.

(1) Thick cable red + (2) Battery case (3) Negative / ground cable black - (4) Plug

(A) HIGHEST LEVEL (B) LOWEST LEVEL

NOTICE 8 Connect the charger positive

terminal to the battery positive terminal, and negative to the negative. 8 When disconnecting the cable

from the battery, start with the negative terminal first.

When connecting the cable to the battery, start with the positive terminal first.

If reversed, the contact of tools on the battery may cause a shortage. 8 DO NOT remove or disconnect

the battery during operation, otherwise the engine cannot be stopped with the starter switch (key).

Instructions for long term storage 1. When storing the generator for long periods of

time, remove the battery, adjust the electrolyte to the proper level, and store in a dry and dark place.

2. The battery naturally discharges while it is stored. Recharge it 1 month in summer, and every 2

months in winter.

9CN-9-10.indd 36 2012/05/25 15:59:08

37 PERIODIC SERVICE

Battery boost starting

DANGER To avoid serious personal injury: 8 Battery gases can explode. Keep

cigarettes, sparks, and flames away from battery. 8 If generator battery is frozen, do

not battery boost start engine. 8 DO NOT connect other end of

negative - jumper cable to negative - terminal of generator battery. 8 Connect to chassis or engine.

When battery boost starting engine, follow the instruc- tions below to safely start the engine. 1. Bring helper battery of the same voltage as

disabled generator within easy cable reach. 2. Put on safety goggles and rubber gloves. 3. Ensure the vent caps are securely in place. (if

equipped) 4. Cover vent caps with damp rags. Do not allow the

rag to touch the battery terminals. 5. Attach the red clamp to the positive (red, + or

pos.) terminal of the dead battery and clamp the other end of the same cable to the positive (red, + or pos.) terminal of the helper battery.

(1) Dead battery (2) Lay a damp rag over vent

caps. (3) Jumper cables (4) Engine block or frame (5) Helper battery

(A) Connect cables in numerical order.

Disconnect in reverse order after use.

6. Clamp the other cable to the negative (black, - or neg.) terminal of the helper battery.

7. Clamp the other end to the engine block or frame of the generator as far from the dead battery as possible.

8. Start the disabled generator. 9. Disconnect the jumper cables in the exact reverse

order of attachment. (Steps 7, 6 and 5). 10. Remove and discard the damp rags.

NOTICE 8 This machine has a 12 volt

negative - ground starting system. 8 Use only same voltage for jump

starting. 8 Use of a higher voltage source

on generators electrical system could result in severe damage to generators electrical system.

Electric Wiring

WARNING To avoid personal injury: Shorting of electric cable or wiring may cause a fire. 8 Check to see if electric cables

and wiring are swollen, hardened or cracked. 8 Keep dust and water away from

all power connections. Loose wiring and terminal parts

make bad connections, be sure to repair them before starting the engine.

Damaged wiring reduces the capacity of electrical parts. Change or repair damaged wiring immediately.

Fuse The electrical system is protected from potential dam- age by fuses. A blown fuse indicates that there is an overload or a short circuit somewhere in the electrical system. If any of the fuses should blow, replace with a new one of the same capacity.

(A) Fuse box

9CN-9-10.indd 37 2012/05/25 15:59:08

38PERIODIC SERVICE

NOTICE 8 Before replacing a blown

fuse, determine why the fuse blew and make any necessary repairs. Failure to follow this procedure may result in serious damage to the generator electrical system. Refer to the troubleshooting section of this manual or a Yamaha dealer for specific information.

[Engine model Z482, D722]

(1) Fuse 3 A : External connection terminal block (2) Fuse 10 A : AC (Accessory Line) (3) Fuse 5 A : Glow (4) Fuse 15 A : Solenoid (5) Fuse 15 A : (spare) (6) Fuse 10 A : (spare)

Fan Belt

Adjusting fan belt tension

WARNING To avoid personal injury: 8 Be sure to stop the engine and

remove the key before checking the belt tension.

8 Be sure to reinstall the detached safety shield after maintenance or checking.

Proper fan belt tension

A deflection of between 12 to 14 mm (0.47 to 0.55 in.) when the belt is pressed in the middle of the span.

1. Stop the engine and remove the key. 2. Apply moderate thumb pressure to belt between

pulleys.

3. If the belt tension is not as specified, loosen the lock nut and turn the adjust nut to get the belt tension within the specified range.

4. Tighten up the lock nut. 5. Replace fan belt if it is damaged.

NOTICE 8 If belt is loosen or damaged

and the fan is damaged, it could result in overheating or insufficient charging. Adjust correctly or replace the belt.

(1) Fan belt (2) Bolt and adjust nut (3) Lock nut

(A) 12 to 14 mm (0.47 to 0.55 in.) (under load of 98 N (22.1 lbs.))

9CN-9-10.indd 38 2012/05/25 15:59:09

39 TRANSPORTING / STORAGE

TRANSPORTING / STORAGE Transporting

WARNING To avoid personal injury: 8 Secure the generator to prevent

movement during operation. 8 DO NOT stand near or under the

generator while it is suspended. 8 The generator is heavy. Utilize

suitable equipment to lift and transport. Keep hands and feet away from under the suspended generator. 8 When transporting the

generator, remove the - battery cable, close the fuel filter cock, and keep the generator level to prevent fuel spillage.

8 Use hangers and wire ropes which are strong enough to withstand the weight of the machine.

1. When transporting the generator, use only suitable transporting equipment, such as crane, fork lift or etc.

2. The generator is equipped with the 2 inlets in the machine bed for forklift forks. Transportability is increased by 2 ways; special forklift openings and 1- point lifting hook.

Use lifting equipment of sufficient capacity.

Model Approx. gross wt. kg (lbs.)

EDL7000SDE [Engine model: Z482] 262 (577)

EDL11000SDE [Engine model: D722] 318 (700)

Storage

WARNING To avoid personal injury: 8 DO NOT clean the machine with

engine running. 8 To avoid the danger of exhaust

fume poisoning, do not operate the engine in a closed building without proper ventilation. 8 When storing the generator just

after running, let the engine cool off.

Before storing the generator for more than a few months, remove any dirt on the machine, and: 1. Remove dirty engine coolant, fill with new coolant

and run the engine for about 5 minutes. When coolant is added, coolant level drops the

first time the engine is started, stop the engine and add more coolant.

2. Remove dirty engine oil, fill with new oil and run the engine for about 5 minutes to let the oil penetrate to all the parts.

3. Check all the bolts and nuts, and tighten if necessary.

4. Remove the battery from the generator, adjust the electrolyte level, and recharge it. Store the battery in a dry and dark place.

5. When the engine is not used for a long period of time, run it for about 5 minutes under no load every 2 to 3 months to keep it free from rust. If the engine is stored without any running, moisture in the air may condense into dew over the sliding parts of the engine, resulting in rust.

6. If you forget to run the engine for longer than 5 to 6 months, apply enough engine oil to the valve guide and valve stem seal and make sure the valves work smoothly before starting the engine.

7. Store the generator in a flat place and remove the key.

8. Do not store the generator in a place where flammable materials such as dry grass or straw are present.

9. When covering the generator for storage, let engine and muffler cool off completely.

10. Operate the engine after checking and repairing damaged wiring or pipes, and clearing flammable materials carried by rodents, insects or birds.

9CN-9-10.indd 39 2012/05/25 15:59:09

40TROUBLESHOOTING

TROUBLESHOOTING WARNING

To avoid personal injury: 8 Always perform any check at STOP condition except for special check in

which operation is required. 8 Do not touch the charging section during operation. 8 Keep your hands and body away from the rotating parts during operation.

If the machine does not function properly, use the following chart to identify and correct the cause.

Generator Trouble Cause Countermeasure

After electrical equipment connected, generator does not operate.

Circuit breaker is off. Turn breaker ON.

Contact of output terminal and socket is bad.

Reinstall.

Malfunction of electrical equipment Request repair.

Not generating Bad contact of brush Check, cleaning and maintenance of contact face and contact force of brush and slip ring.

( Danger: All works should be performed when stopped)

Circuit breaker can not be operated. Overload Reduce load.

Short circuit of load circuitry connected to output section

Repair load.

Output cannot be obtained. Rotation goes slow. Voltage drops. Breaker turns off.

Initial current is too much. (e.g. motor load)

Reduce load.

Overload Reduce load.

Engine indicates loaded condition. Short circuit of generator wiring Stop immediately. Request for repair.

Easy Checker Trouble Cause Countermeasure

When the key is turned, the lamp doesnt light on.

Bulb is defective. Replace

Component or wiring defect of charging circuit

Check, repair

The water temperature lamp lights on when operating.

Engine overheating. See Precaution at overheating in Radiator section. (See page 34)

Water temperature sensor faulty. Replace the water temperature sensor.

Water temperature sensor wiring faulty. Repair the wiring.

The oil pressure lamp lights on when operating.

Insufficient engine oil. Add engine oil.

Lubricating system in trouble. Check the system.

Oil pressure sensor faulty. Replace the sensor.

Oil pressure sensor wiring faulty. Repair the wiring.

The battery charge lamp lights on when operating.

Poor contact of sub winding. Connect tightly.

Sub winding problem. Check the sub winding.

9CN-9-10.indd 40 2012/05/25 15:59:09

41 TROUBLESHOOTING

Engine Trouble Cause Countermeasure

Not started. Not turned or slow turning.

Battery trouble. Replacement of battery.

Insufficient battery charge. Recharge battery.

Slow turning at cold circumstance due to high viscosity of engine oil. Fuse blown out (Slow blow fuse)

Replace engine oil to D5W40 or D10W30 for cold.

Replace fuse.

Terminal cover open. Close terminal cover. Fix terminal cover with panel lock bolts.

Normal turning, but not started.

Fuel shortage. Refuel.

Fuel does not flow. Check fuel filter. If filter is dirty, replace. Check fuel tank. Remove the settled

impurities or moisture.

Air and water are contained in fuel supply line.

Check pipe and fastening clamp. If any damage exists, replace or repair.

Relieve air. Remove water inside of fuel tank and

filter.

Injection pipe is loosened. Re-tighten.

Engine starts but stops immediately. Engine oil shortage. Add engine oil to upper limit of gauge.

Rotation is irregular. Fuel shortage. Refuel.

Fuel does not flow. Check fuel filter. If filter is dirty, replace. Check fuel tank. Remove the settled

impurities or moisture.

Air and water are contained in the fuel supply line.

Check pipe and fastening clamp. If any damage exists, replace it, or repair.

Relieve air.

Remove water inside of fuel tank and filter.

Injection pipe is loosened. Re-tighten.

Engine suddenly stops. Fuel shortage. Refuel.

Insufficient engine oil. Fill oil.

Water temperature is too high. Insufficient cooling water. Loosened water pump belt. Blockage of radiator.

Fill cooling water. Adjust belt tension. Clean.

Terminal cover open. Close terminal cover. Fix terminal cover with panel lock bolts.

Insufficient output. When loaded, rotation goes slow.

Choke of air cleaner element. Replace air cleaner element.

Choke of fuel system. Check.

Choke of fuel filter. Element cleaning.

Oil deterioration. Replace engine oil.

Overload. Refer to generator.

Coolant leaks out. Insufficient cooling water. Fill cooling water.

Loosened fan belt. Adjust belt tension.

Blockage of radiator. Clean.

Exhaust gas is bad. Choke of air cleaner element. Clean air cleaner element.

Engine oil is over filled. Remove oil to upper limit of gauge.

Fuel quality is bad. Replace fuel with good quality fuel.

Abnormal sound Large vibration.

Crack of vibration-proof rubber. Replace.

Others. Check, repair.

If you have any questions, contact a Yamaha dealer.

9CN-9-10.indd 41 2012/05/25 15:59:09

42AUTOMATIC START/STOP UNIT (A S/S UNIT)

AUTOMATIC START/STOP UNIT (A S/S UNIT) To connect the machine to the A S/S UNIT the generator is equipped with the ectt on the left side panel of the control panel. To connect the exterior apparatus with the machine, perform the following instructions;

1. Remove the terminal taps cover. 2. Connect the unit to the ectt with the wiring

harnesses, following the operators manual of the A S/S unit.

3. To assemble the ttc, set the ttc. For nomenclature and connection of terminal taps are referred to the WIRING DIAGRAMS section. (See page 4344)

(1) Plate (2) Exterior connection terminal taps (ectt) (3) Terminal taps cover (ttc)

9CN-9-10.indd 42 2012/05/25 15:59:09

43 WIRING DIAGRAM

G E

N E

R AT

O R

B

LO C

K

E N

G IN

E

B LO

C K

C O

N T

R O

LB O

X B

LO C

K

M W

R

R/W

L

L L

L GLG LG /R

L GLG LG /R

W Br BR

BR Br

5m m2

BR 5m

m2

BR 3m

m2

LG 2m

m2

GR 3m

m2

BR

B/W

GR

R

G

3mm2

BR BR

R/B G

O P

3mm 2

GR G

O R/B

W/ B

3mm 2

GR

3mm 2

3mm 2

LG 2m

m2

R 5m

m2

BR 3m

m2 W W

B/Y

5m m2

2m m2

3m m2

5mm 2

5mm 2

R 2m

m2

BR 5m

m2 BR

5m m2

L/W 2mm 2

L/W 2mm 2

L 2mm 2

L 2mm 2

R B B

L L

L L

O BR

R R

R R

R R/B

R /B

Y/W Y

/W

O BR

BR

GR

G Y

O Y

P P

O

LG

LG

BR

Y Y

5mm 2

5mm 2

2mm 2

2mm 2

2mm 2

2mm 2

2mm 2

2mm 2

2mm 2

2mm 2

BR5mm 2

BR 5m

m2 BR

5m m2

BR 5m

m2

G5mm 2

G5mm 2

G5mm 2

G 5m

m2 G

5m m2

GR 5m

m2

L 5m

m2

5mm 2

2m m2

2m m2

5mm 2

2mm 2

2mm 2

L 5m

m2

R 5m

m2 R

5m m2

R 5m

m2 R

5m m2

R 5m

m2

R 5m

m2 R

5m m2

W 5m

m2 W

5m m2

R 3m

m2

R3 mm

2

G3 mm

2

W 3m

m2

R3mm 2

R3mm 2

W 5m

m2 W

5m m2

W5mm 2

L 5m

m2

G 5m

m2

W5mm 2

PIL OT

LA MP

V-M ET

ER P

L V

1

N F

B

FU LL

PO WE

R SW

ITC H

AC O

UT PU

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RM IN

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H TE

RM IN

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CO MB

IN AT

IO N

LA MP

HO UR

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ST AR

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ITC H

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SW

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OX

SL OW

B LO

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15 A

10 A

5A 3A

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LA TO

R

BA TT

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GL OW

P LU

G ST

OP S

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SW IT

CH

GL OW

R EL

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R R

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L AM

P TI

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MP ER

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DI OD

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1 2

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4 0

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7 8

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R/WR/W

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Y Y/W Y

G O

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Y O

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GR Y/W

Y/R W/

R W/

B R/B

B/W B/Y

Y/B R

Y

W/ B

R/B B /W

R/W R Y OR/ B

Y/W

R/W

B/Y Y/B

G Y

Y G

G O

L/WL/W

EM ER

GE NC

Y UN

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-1

1 2

3 4

5 6

7

L1 4-3

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L5 -30

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(G FC

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M O

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BR B

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AC K

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LG G

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30 AC 19 50RS 1

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L2 L1LB WS OS EA RT

H

A B C F G H I J K L

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3 5

3 3

4 5

5 6

1 2

1 1

2 2

EDL7000SDE (120 V/240 V)

WIRING DIAGRAM

9CN-9-10.indd 43 2012/05/25 15:59:09

44WIRING DIAGRAM

G E

N E

R AT

O R

B

LO C

K

E N

G IN

E

B LO

C K

C O

N T

R O

LB O

X B

LO C

K

M W

R R

R R

R/W

R/W

R/W

L

L

LG LG

L L

P P

Y L

G

L

L L

LG 2m

m2

GR 3m

m2

BR

B/W

GR R

G

3mm2

BR BR

R/B G

O P

3mm 2

GR G

O R/B

W/ B

3mm 2

GR

3mm 2

3mm 2

LG 2m

m2

R 5m

m2

BR 3m

m2 W W

B/Y

5m m2

2m m2

3m m2

5mm 2

5mm 2

R 2m

m2

L/W 2mm 2

L/W 2mm 2

L 2mm 2

L 2mm 2

R B B

L L

L L

O BR

R R

R R

R R/B

R /B

Y/W Y

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O BR

BR

GR

G Y

O Y

P P

O

LG

LG

BR

Y Y

5mm 2

5mm 2

2mm 2

2mm 2

2mm 2

2mm 2

2mm 2

2mm 2

2mm 2

2mm 2

L8mm 2

R8mm 2

G8mm 2

G5mm 2

L5mm 2

Y3mm 2

L3mm 2

G3mm 2

G 8m

m2 8m

m2 8m

m2 G

8m m2

G 8m

m2

G 5m

m2

5mm 2

2m m2

2m m2

5mm 2

2mm 2

2mm 2

R 8m

m2

G5mm 2

W5mm 2

L 8m

m2

R 8m

m2

R 5m

m2

R5mm 2

BR5mm 2

BR 5m

m2 W

8m m2

W 3m

m2 Y

3m m2

W 3m

m2

W 8m

m2

L3 mm

2 G3mm 2

W 8m

m2

R 8m

m2

W R L

L LW

W8mm 2

G 8m

m2

L 8m

m2

PIL OT

LA MP

DI OD

E U

NI T

CO ND

EN SE

R

V-M ET

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L V

1

EA RT

H T

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CO MB

IN AT

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LA MP

HO UR

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ST AR

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AV R

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B LO

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0A )

15 A

10 A

5A 3A

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LA TO

R

BA TT

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ST AR

TE R

GL OW

P LU

G ST

OP S

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OI D

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R EL

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R R

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MP ER

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DI OD

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DI OD

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1 A

R/WR/W

LG

Y

Y

X W

Y/W Y

G O

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Y O

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GR Y/W

Y/R W/

R W/

B R/B

B/W B/Y

Y/B R

Y

W/ B

R/B B/W

R/W R Y OR/ B

Y/W

R/W

B/Y Y/B

G Y

Y G

G O

L/WL/WL/W

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GE NC

Y UN

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-1

SE PA

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LY E

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1 2

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L6 -30

R (24

0V )

L5 -30

R (12

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5-2 0R

(G FC

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5-2 0R

(G FC

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0V )

CS 63

69 (50

A) (12

0/2 40

V) C.

P.2 0A

C. P.2

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C. P.3

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+

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D G

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Y W

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FW

R/W R/W

R/W R/W

R/W R/W

Y/R Y/R

R/W R/W

R/W R/W

B/W

4 3

2 1

G W

LG 4

3 2

1 1A

30 AC 19 50

R

2m m2

GY OR/ B

R/ W

R/ W

W /R B/ Y

Y/ R L/W

30 AC 19 50RS 1

RS 2

L2 L1LB WS OS EA RT

H

A B C F G H I J K L

M

3 5

3 3

4 5

5 6

1 2

1 1

2 2

5A

8A

1 2 3

1 4

2

3 5

N FB

EDL11000SDE (120 V/240 V)

9CN-9-10.indd 44 2012/05/25 15:59:09

45 WARRANTY

YAMAHA MOTOR CORPORATION, U.S.A. EDL SERIES GENERATORS

3-YEAR LIMITED WARRANTY Yamaha Motor Corporat ion, U.S.A. hereby warrants that new Yamaha generators purchased from an authorized Yamaha generator dealer in the United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations.

THE PERIOD OF WARRANTY Any new EDL- series Yamaha generator purchased from an authorized Yamaha generator dealer in the United States wil l be warranted against defects in material or workmanship for a period of three (3) years from date of purchase for pleasure or (except EF1000iS) commercial use, subject to exclusions noted herein. Yamaha EF1000iS generators purchased for commercial use from an authorized Yamaha generator dealer in the continental United States wil l be warranted against defects in materials or workmanship for a period of two (2) years from the date of purchase, subject to exclusions noted herein.

DURING THE PERIOD OF WARRANTY any authorized Yamaha generator service dealer will, free of charge, repair or replace, at Yamahas option, any part judged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the products warranty period. All parts replaced under warranty become the property of Yamaha Motor Corporation, U.S.A.

GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a. Installation of parts or accessories that are

not qual i tat ive ly equivalent to genuine Yamaha parts.

b. Abnormal strain, neglect, or abuse. c. Lack of proper maintenance. d. Accident or collision damage.

SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance.

THE CUSTOMERS RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the generator as

specified in the appropriate Owners Manual. 2. G ive no t i ce to an au thor ized Yamaha

consumer generator service dealer of any and all apparent defects within ten (10) days

af ter d iscovery, and make the machine available at that t ime for inspection and repairs at such dealers place of business. You may locate your nearest authorized Yamaha generator service dealer online at www.yamaha-motor.com.

EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation, U.S.A. also warrants to the ultimate purchaser and each subsequent purchaser of each 1995 and later Yamaha Generator covered by this warranty that the product is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet t hese s t and ard s w i t h in t he pe r i o d l i s ted immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/ or lack of proper maintenance are not covered by this warranty. All 1995 and Later EDL Models Three (3) years from the original purchase date

WARRANT Y TRANSFER : To t ransfer any remaining warranty from the original purchaser to any subsequent purchaser, it is imperative that the unit be inspected and registered for warranty by an authorized Yamaha consumer generator dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days af ter transfer. A reasonable dealer imposed fee may be charged for the inspection.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES N O O T H E R W A R R A N T Y O F A N Y K I N D , E X P R E S S E D O R I M P L I E D . A L L I M P L I E D WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY D I S C L A I M E D B Y Y A M A H A M O T O R CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY

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46WARRANTY

ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR L I M I T A T I O N O F I N C I D E N T A L O R CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

YAMAHA MOTOR CORPORATION, U.S.A. Post Office Box 6555

Cypress, California 90630

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47 WARRANTY

WARRANTY QUESTIONS AND ANSWERS Q. What costs are my responsibility during the

warranty period? A. The customers responsibility includes all

costs of normal maintenance service, non- warranty repairs, accident damages, as well as oil and spark plugs.

Q. What are some examples of abnormal strain, neglect, or abuse?

A. These terms are general and overlap each other in areas. Specific examples include: Running the machine out of oil; lack of proper maintenance; operating the machine with a broken or damaged par t which causes another part to fail; and so on. If you have any specif ic quest ions on operat ion or maintenance, please contact your dealer for advice.

Q. Does the warranty cover incidental costs such as transportation due to a failure?

A. No. The warranty is limited to repair of the machine itself.

Q. May I perform any or all of the recommended maintenance shown in the Owners Manual instead of having the dealer do them?

A. Yes, if you are a qualified mechanic and fo l low the procedures spec i f ied in the O w n er s an d Se r v i c e M anu a l . We d o recommend, however, that items requiring special tools or equipment be done by a Yamaha generator dealer.

Q. Will the warranty be void or cancelled if I do not operate or maintain my new Yamaha exactly as specified in the Owners Manual?

A. No. The warranty on a new Yamaha cannot be voided or cancelled.

However, if a particular failure is caused by operation or maintenance other than as shown in the Owners Manual, that failure may not be covered under warranty.

Q. What responsibility does my dealer have under this warranty?

A. Each Yamaha generator dealer is expected to: 1. Check the operation of the generator

before sale. 2. Explain the operation, maintenance, and

w a r r a n t y r e q u i r e m e n t s t o y o u r satisfaction at the time of sale, and upon your request at any later date.

In addition, each Yamaha generator dealer is held responsible for his setup, service and warranty repair work.

Q. Is the warranty t ransferable to second owners?

A. Yes. The remainder of the existing warranty can be transfered upon request.

The unit has to be inspected and reregistered by an authorized Yamaha generator dealer for the policy to remain effective.

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha generator dealer within the continental United States. Be su re t o b r i n g yo u r wa r r an t y r e g i s t r a t i o n identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since al l warranty mat ters are handled at the dealer level, this person is in the best position to help you. If you are stil l not satisfied and require additional assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPARTMENT

P.O. BOX 6555 Cypress, California 90630

CHANGE OF ADDRESS

T h e f e d e r a l g o v e r n m e n t r e q u i r e s e a c h manufacturer to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase. If you should move af ter you have purchased your new generator, please advise us of your new address by sending a postcard listing your Yamaha model name, engine number, dealer number (or dealers n a m e ) a s i t i s s h o w n o n y o u r w a r r a n t y ident i f icat ion, your name and new mai l ing address. Mail to:

YAMAHA MOTOR CORPORATION, U.S.A. WARRANTY DEPARTMENT

P.O. Box 6555 Cypress, California 90630

This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

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YAMAHA OUTDOOR POWER EQUIPMENT CALIFORNIA EVAPORATIVE EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Yamaha Motor Corporation, USA are pleased to explain the evaporat ive emission contro l systems warranty on your 2006 or later outdoor power equipment. In California, new equipment that use small off-road engines must be designed, built, and equipped to meet the States stringent anti- smog standards. Yamaha Motor Corporation, USA must warrant the evaporative emission control system on your outdoor power equipment for the period listed below provided there has been no abuse, neglect, or improper maintenance of your equipment.

Your evaporative emission control system may include parts such as: carburetors, fuel tanks, fuel lines, fuel caps, valves, canisters, filters, vapor hoses, clamps, connectors, and other associated components. For engines less than or equal to 80 cc , on ly the fue l tank i s sub jec t i s the e v a p o r a t i v e e m i s s i o n c o n t r o l w a r r a n t y requirements of this section.

MANUFACTURERS WARRANTY COVERAGE: This evaporative emission control system is warranted for three years. If any evaporative emission-related par t on your equipment is defective, the part will be repaired or replaced by Yamaha.

OWNERS WARRANTY RESPONSIBILITIES: 9 As the outdoor power equipment owner, you

are responsible for the performance of the required maintenance listed in your owners manual. Yamaha recommends that you retain all receipts covering maintenance of your outdoor power equipment, but Yamaha cannot deny warranty solely for the lack of receipts.

9 As the outdoor power equipment owner, you should however be aware that Yamaha may deny you warranty coverage if your outdoor power equipment or a part has failed due to abuse, neglect, or improper maintenance, or unapproved modifications.

9 You are responsible for presenting your outdoor power equipment to a Yamaha service center as soon as the problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have a question regarding your warranty coverage, you should contact Yamaha Customer Relations at 1-800-962-7926.

YAMAHA MOTOR CORPORATION, USA Post Office Box 6555

Cypress, California 90630

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49 WARRANTY

YAMAHA MOTOR CORPORATION, U.S.A. SMALL OFF ROAD ENGINES CALIFORNIA EMISSION CONTROL WARRANTY YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Yamaha Motor Corporation, U.S.A. are pleased to explain the emission control system warranty on your 2008 and later Small Off Road Engine (SORE). In California, new SORE engines must be designed, built and equipped to meet the States stringent anti-smog standards. Yamaha must warrant the emission control system on your SORE engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your SORE engine.

Your emission control system may include parts such as the carburetor or fuel-injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Yamaha will repair your SORE engine at no cost to you including diagnosis, parts and labor.

MANUFACTURERS WARRANTY COVERAGE

The 2008 and later SORE engines are warranted for three years. If any emissions-related part on your engine is defective, the part will be repaired or replaced by Yamaha.

OWNERS WARRANTY RESPONSIBILITIES

9 As the SORE engine owner, you are responsible for the performance of the required maintenance listed in your owners manual. Yamaha recommends that you retain all receipts covering maintenance on your SORE engine, but Yamaha cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

9 As the SORE engine owner, you should however be aware that Yamaha may deny you warranty coverage if your SORE engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

9 You are responsible for presenting your SORE engine to a Yamaha dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact the Yamaha Customer Relations Department at 1-800-962-7926.

Yamaha Motor Corporation, U.S.A. warrants to the ultimate purchaser and each subsequent purchaser thereafter that each new SORE engine certified for sale and registered in California are:

1. Designed, built, and equipped so as to conform, at the time of sale, with all applicable regulations adopted by the California Air Resources Board, and

2. All warranted parts are free from defects in material and workmanship for the warranty period of the SORE engine or the period prior to the first scheduled replacement point of the warranted part as required by the maintenance schedule, if applicable, whichever is less. A defect exists when a deficiency in material or workmanship is such that an emission-related warranted part does not function as designed.

The warranty period begins on the date that the SORE engine is delivered to an ultimate purchaser or on the date it is first placed in service.

The warranty on emissions-related parts will be interpreted as follows: (1) Any warranted part that is not scheduled for replacement as required maintenance in the written

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instructions required by subsection (d) must be warranted for the warranty period defined in Subsection (b)(2). If any such part fails during the period of warranty coverage, it must be repaired or replaced by the manufacturer according to Subsection (4) below. Any such part repaired or replaced under the warranty must be warranted for the remaining warranty period.

(2) Any warranted part that is scheduled only for regular inspection in the written instructions required by subsection (d) must be warranted for the warranty period defined in Subsection (b)(2). A statement in such written instructions to the effect of repair or replace as necessary will not reduce the period of warranty coverage. Any such part repaired or replaced under warranty must be warranted for the remaining warranty period.

(3) Any warranted part that is scheduled for replacement as required maintenance in the written instructions required by subsection (d) must be warranted for the period of time prior to the first scheduled replacement point for that part. If the part fails prior to the first scheduled replacement, the part must be repaired or replaced by the engine manufacturer according to Subsection (4) below. Any such part repaired or replaced under warranty must be warranted for the remainder of the period prior to the first scheduled replacement point for the part.

(4) Repair or replacement of any warranted part under the warranty must be performed at no charge to the owner at a warranty station.

(5) Notwithstanding the provisions of Subsection (4) above, warranty services or repairs must be provided at all manufacturer distribution centers that are franchised to service the subject engines.

(6) The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective, provided that such diagnostic work is performed at a warranty station.

(7) The manufacturer is liable for damages to other engine components proximately caused by a failure under warranty of any warranted part.

(8) Throughout the emissions warranty period defined in Subsection (b)(2), the manufacturer must maintain a supply of warranted parts sufficient to meet the expected demand for such parts.

(9) Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner. Such use will not reduce the warranty obligations of the manufacturer.

(10) Add-on or modified parts that are not exempted by the Air Resources Board may not be used. The use of any non-exempted add-on or modified parts will be grounds for disallowing a warranty claim. The manufacturer will not be liable to warrant failures of warranted parts caused by the use of a non- exempted add-on or modified part.

(11) The manufacturer issuing the warranty shall provide any documents that describe that manufacturers warranty procedures or policies within five working days of request by the Air Resources Board.

WARRANTED PARTS INCLUDE the following:

1. Fuel Metering System Carburetor and internal parts (or fuel injection system) Air/fuel ratio feedback and control system Cold start enrichment system

2. Air Induction system Controlled hot air intake system Intake manifold Air filter

3. Ignition System Spark plugs* Magneto or electronic ignition system Spark advance/retard system

4. Exhaust Gas Recirculation (EGR) System EGR valve body, and carburetor spacer if applicable EGR rate feedback and control system

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51 WARRANTY

5. Air Injection System Air pump or pulse valve Valves affecting distribution of flow Distribution manifold

6. Catalyst or Thermal Reactor System Catalytic converter Thermal reactor Exhaust manifold

7. Particulate Controls Traps, filters, precipitators, and any other device used to capture particulate emissions

8. Miscellaneous Items Used in Above Systems Vacuum, temperature, and time sensitive valves and switches Electronic controls Hoses, belts, connectors, and assemblies

9. Engine components damaged due to a failure under warranty or a warranted part

*The original spark plug(s) are warranted for the period of replacement indicated in the Owners Manual and not the useful life of the SORE engine (see your Owners Manual).

DURING THE PERIOD OF THIS WARRANTY

Yamaha Motor Corporation, U.S.A. will repair or replace any warranted part deemed defective by Yamaha during the scope of the warranty without charge to the owner, including parts, labor, and diagnosis. This work must be done at an authorized Yamaha dealer. Give notice to an authorized Yamaha dealer of any apparent defects(s) within a reasonable period of time after discovery. The SORE engine must be made available for inspection by an authorized Yamaha dealer.

OWNERS RESPONSIBILITY:

The owner of the SORE engine is responsible for the performance of required maintenance (see your Owners Manual). Receipts and maintenance records covering the performance of regular maintenance should be retained in the event questions arise concerning maintenance. The receipts should be transferred to each subsequent owner of this SORE engine.

The emission control systems of your Yamaha SORE engine were designed, built, tested, and certified as being in conformity with California emission control regulations using genuine Yamaha parts. Accordingly, it is recommended that any replacement part(s) used for maintenance, replacement, or repair of emission control systems be Yamaha parts. The owner may elect to have maintenance, replacement, or repair of the emission control devices and systems performed by any repair establishment or individual, and may elect to use parts other than Yamaha parts for such maintenance, replacement, or repair without invalidating this warranty. However, the cost of such service or parts will not be covered under the warranty.

EXCLUSIONS: No warranty coverage will be allowed if the part(s) failure was caused by owner/operator abuse, neglect, tampering, improper adjustment unless performed by a dealer during warranty repair work, modification, misuse, alteration, or improper maintenance (see your Owners Manual).

Use of parts which are not qualitatively equivalent to genuine Yamaha parts, improper service, or lack of required maintenance which causes failure of a warranted part may constitute abuse and/or improper service, thereby invalidating warranty liability hereunder.

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This warranty does not cover damage resulting from accidents, acts of nature, or other events or occurrences beyond the control of Yamaha. Yamaha Motor Corporation, U.S.A. expressly disclaims responsibility for any and all consequential damages, such as loss of time, inconvenience, loss or use of the SORE engine, or commercial loss.

YAMAHA MOTOR CORPORATION, U.S.A. Post Office Box 6555

Cypress, California 90630

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YAMAHA EXTENDED SERVICE (Y.E.S.)

Keep your Yamaha Generator protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.).

9 Y.E.S. is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction. You get uninterrupted factory-backed coverage for extra peace of mind.

9 Y.E.S. is flexible. You can choose the plan thats right for you: 12 months, 24 months or 36 months coverage.

9 Y.E.S. is administered by the same Yamaha people that handle your warranty - and it shows in the comprehensive coverage benefits. There are no hour limitations and Y.E.S. covers manufacturing defects just like your warranty. See a sample contract at your Yamaha dealer and see how comforting uninterrupted factory backed protection can be.

9 There are no out-of-pocket expenses for covered repairs. Yamaha will never ask you to pay a deductible.

9 Nationwide coverage. Y.E.S. coverage is honored at any authorized Yamaha Outdoor Power Equipment Service dealer.

9 Y.E.S. coverage is transferable to a new owner if you sell or trade-in. That can make you Yamaha much more valuable.

This excellent Y.E.S. plan coverage is only available to Yamaha owners like you, and only while your Yamaha is still within the Yamaha Limited Warranty period. So visit your authorized Yamaha dealer to get all the facts. He can show you how easy it is to protect your investment with Yamaha Extended Service.

Special note: If visiting your dealer isnt convenient, contact Yamaha with your Primary ID number (your frame number). Well be happy to help you get the Y.E.S. coverage you need.

Yamaha Service Marketing P.O. Box 6555

Cypress, CA 90630 1-866-YES-EXTD (1-866-937-3983)

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Manualsnet FAQs

If you want to find out how the EDL7000SDE Yamaha works, you can view and download the Yamaha EDL7000SDE, EDL11000SDE Owner's Manual on the Manualsnet website.

Yes, we have the Owner's Manual for Yamaha EDL7000SDE as well as other Yamaha manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Owner's Manual should include all the details that are needed to use a Yamaha EDL7000SDE. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Yamaha EDL7000SDE, EDL11000SDE Owner's Manual is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This Yamaha EDL7000SDE, EDL11000SDE Owner's Manual consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download Yamaha EDL7000SDE, EDL11000SDE Owner's Manual free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print Yamaha EDL7000SDE, EDL11000SDE Owner's Manual, simply download the document to your computer. Once downloaded, open the PDF file and print the Yamaha EDL7000SDE, EDL11000SDE Owner's Manual as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.