Yamaha EF1000iS v2 Owner's Manual PDF

Generator

LIT-19626-01-19 7CG-28199-10PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 04 904 1.2 1 !

EF1000iS

OWNERS MANUAL

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AE00012

IDENTIFICATION NUMBER RECORDS Record your Primary I.D., and serial num- bers in the spaces provided, to assist you in ordering spare parts from a Yamaha dealer. Also record and keep these I.D. numbers in a separate place in case your machine is stolen.

AE00011

MACHINE IDENTIFICATION The machine serial number is stamped in the location as shown.

NOTE: The first three digits of these numbers are for model identification; the remaining dig- its are the unit production number. Keep a record of these numbers for reference when ordering parts from a Yamaha deal- er.

AE00002

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

PRI-I.D. NUMBER

PRI-I.D. CODE SERIAL No.

EF1000iS OWNERS MANUAL

2004 by Yamaha Motor Corporation, U.S.A. 1st Edition, March 2004

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-19626-01-19

MODEL

790-065b

7CG-24163-00

AE00022

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NOTE: 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 your Yamaha deal- er.

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

AE00032

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

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

- The Safety Alert Symbol means ATTEN- TION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

w Failure to follow WARNING instructions could result in severe injury or death to the engine operator, a bystander, or a person inspecting or repairing the engine.

cC A CAUTION indicates special precautions that must be taken to avoid damage to the engine.

NOTE: A NOTE provides key information to make procedures easier or clearer.

7CG-28199-10 4/1/04 3:13 PM Page B

AE00041

CONTENTS

SPARK PLUG INSPECTION.............22

CARBURETOR ADJUSTMENT.........22

ENGINE OIL REPLACEMENT ..........23

MUFFLER SCREEN AND SPARK ARRESTER .......................................24

AIR FILTER........................................26

FUEL TANK FILTER..........................27

TROUBLESHOOTING..........................28

STORAGE.............................................30

DRAIN THE FUEL .............................30

ENGINE .............................................30

EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS ............31

SPECIFICATIONS ................................32

DIMENSIONS ....................................32

ENGINE .............................................32

GENERATOR ....................................32

WIRING DIAGRAM...............................33

LIMITED WARRANTY (EF- AND EDL-SERIES)..........................................1

LOCATION OF IMPORTANT LABELS ..3

SAFETY INFORMATION........................4

EXHAUST FUMES ARE

POISONOUS .......................................4

FUEL IS HIGHLY FLAMMABLE AND POISONOUS .......................................4

ENGINE AND MUFFLER MAY

BE HOT................................................4

ELECTRIC SHOCK PREVENTION.....5

CONNECTION NOTES .......................6

CONNECTION.....................................6

EXTENSION CORD NOTES ...............6

CONTROL FUNCTION ...........................7

DESCRIPTION ....................................7

CONTROL PANEL...............................7

OIL WARNING SYSTEM.....................8

ENGINE SWITCH................................8

ECONOMY CONTROL SWITCH.........8

DC PROTECTOR ................................9

FUEL TANK CAP AIR VENT KNOB....9

FUEL COCK KNOB .............................9

PRE-OPERATION CHECK...................10

FUEL..................................................10

ENGINE OIL ......................................11

GROUND (Earth) ...............................11

OPERATION .........................................12

STARTING THE ENGINE..................12

APPLICATION RANGE .....................14

CONNECTION...................................15

STOPPING THE ENGINE .................19

PERIODIC MAINTENANCE .................20

MAINTENANCE CHART ...................20

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1

AE01120

YAMAHA MOTOR CORPORATION U.S.A. EF- AND EDL-SERIES GENERATOR LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby war- rants that new Yamaha consumer generators pur- chased from an authorized Yamaha consumer generator dealer in the continental United States will be free from defects in material and workman- ship for the period of time stated herein, subject to certain stated limitations.

THE PERIOD OF WARRANTY Any new EF- series or EDL-series Yamaha Generator pur- chased for private, non-commercial use from an authorized Yamaha consumer generator dealer in the continental United States will be warranted against defects in material or work- manship for a period two (2) years from date of purchase, subject to exclusions noted herein. Any Yamaha non-commercial generator purchased and utilized for commercial or rental applications will be warranted for a period one (1) year from the date of purchase, subject to exclusions noted herein.

DURING THE PERIOD OF WARRANTY any authorized Yamaha consumer generator dealer will, free of charge, repair or replace, at Yamahas option, any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be war- ranted for the balance of the products warranty period. All parts replaced under warranty become 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

qualitatively 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 rou- tine maintenance.

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

fied in the appropriate Owners Manual;

2. Give notice to an authorized Yamaha con- sumer generator dealer of any and all appar- ent defects within ten (10) days after discov- ery, and make the unit available at that time for inspection and repairs at such dealers place of business.

WARRANTY TRANSFER: To transfer the warran- ty from the original purchaser to any subsequent purchaser(s), it is imperative that the unit be inspected and registered for warranty by an autho- rized Yamaha consumer generator dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service. In no case will the warranty be extended beyond the original peri- od.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WAR- RANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR 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 LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUEN- TIAL 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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2

WARRANTY QUESTIONS AND ANSWERS

Q. Is the warranty transferable to second own- ers?

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 sure to bring your warranty registration identifica- tion or other valid proof of the original date of pur- chase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the deal- er level, this person is in the best position to help you. If you are still not satisfied and require addi- tional assistance, please write:

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

P.O. BOX 6555 Cypress, California 90630

CHANGE OF ADDRESS

The federal government requires each manufac- turer 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 after you have purchased your new generator, please advise us of your new address by sending a post- card listing your Yamaha model name, engine number, dealer number (or dealers name) as it is shown on your warranty identification, your name and new mailing 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.

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 part which causes anoth- er part to fail; and so on. If you have any specific questions on operation or mainte- nance, 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 follow the procedures specified in the Owners and Service Manual. We do 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

warranty requirements to your 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.

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HOT EXHAUST 7VV-28176-10

AE00062

LOCATION OF IMPORTANT LABELS Please read the following labels carefully before oper- ating this machine.

NOTE: Maintain or replace safety and instruction labels, as necessary.

WARNINGq

READ THE OWNERS MANUAL AND ALL LABELS BEFORE OPERATING.8 ONLY OPERATE IN WELL-VENTILATED AREAS. EXHAUST GAS CONTAINS POISONOUS CARBON MONOXIDE. 8

CHECK FOR SPILLED FUEL OR FUEL LEAKS.8 STOP ENGINE BEFORE REFUELING.8 DO NOT OPERATE NEAR FLAMMABLE MATERIALS.8 ELECTROCUTION CAN OCCUR IF GENERATOR IS USED IN RAIN, SNOW, OR NEAR WATER. KEEP THIS UNIT DRY AT ALL TIMES.

8

ELECTROCUTION OR PROPERTY DAMAGE CAN OCCUR. DO NOT CONNECT THIS GENERATOR TO ANY BUILDINGS ELECTRICAL SYSTEM UNLESS AN ISOLATION SWITCH HAS BEEN INSTALLED BY A LICENSED ELECTRICIAN. REFER TO THE OWNERS MANUAL.

8

7VV-24162-10

1

5

0 2 4 6 8 1 0

ENGINE AIR INDEX ( C a l i f o r n i a o n l y )

LEAST CLEANMOST C L E A N N O T E : T H E L O W E R T H E A I R I N D E X , T H E L E S S T H E P O L L U T I O N

F O R T H E F O L L O W I N G U S E :

T H I S E N G I N E I S C E R T I F I E D T O B E E M I S S I O N C O M P L I A N T

MODERATE INTERMEDIATE EXTENDED CHECK OWNERS M A N U A L F O R F U R T H E R D E T A I L S

T H I S L A B E L T O B E R E M O V E D B Y T H E U L T I M A T E P U R C H A S E R O N L Y !

IMPORTANT ENGINE INFORMATION ENGINE FAMILY : zzzzzzzzzzzzE M

REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.

YAMAHA MOTOR CO. LTD

DISPLACEMENT: VALVE LASH (A)

rpm

NO OTHER ADJUSTMENTS NEEDED.

ENGINE OIL:

IDLE SPEED:

FUEL: THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED GASOLINE.

IGNITION TIMING & IDLE MIXTURE zzzJ IN:

TYPE

z.zz~z.zz EX:z.zz~z.zz

zzzz~zzzz AT NO LOAD

SESAE 10W-30 THIS ENGINE MEETS zzzz-zzzz CALIFORNIA EMISSION REGULATIONS FOR SMALL OFF-ROAD ENGINES. THIS ENGINE CONFORMS TO PHASE 2 U.S.EPA REGULATIONS FOR SMALL NONROAD ENGINES. EMISSIONS COMPLIANCE PERIOD:CATEGORY A (EPA) 7VV-2179R-00

4

3

OIL

zzzzzz

AC output zzHz Rated zzzVA zzzV Phase Single DC output zzV zA Fuel Gasoline

YAMAHA MOTOR CO., LTD MADE IN JAPAN

7VV-24164-10

2

STARTING INSTRUCTION

8Disconnect all

electrical devices.

Turn ECON. switch to OFF

Open fuel cap vent

Turn fuel knob ON

Turn engine switch to ON

Pull choke knob out

Pull recoil starter

Push choke knob in

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8

8

8

8

8

8

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AE00071

SAFETY INFORMATION

AE00072

EXHAUST FUMES ARE POISONOUS 9 Never operate the engine in a closed area or it

may cause unconsciousness and death within a short time. Operate the engine in a well ventilated area.

AE01018

FUEL IS HIGHLY FLAMMABLE AND POISONOUS 9 Always turn off the engine when refuelling. 9 Never refuel while smoking or in the vicinity of an

open flame. 9 Take care not to spill any fuel on the engine or

muffler when refuelling. 9 If you swallow any fuel, inhale fuel vapor, or allow

any to get in your eye(s), see your doctor immedi- ately. If any fuel spills on your skin or clothing, immediately wash with soap and water and change your clothes.

9 When operating or transporting the generator, be sure it is kept upright. If it tilts, fuel may leak from the carburetor or fuel tank. Also, be sure the fuel tank cap air vent knob is tightened when transporting the generator.

4

741-081

741-082

741-083

741-084

741-085

AE01019

ENGINE AND MUFFLER MAY BE HOT 9 Place the generator in a place where pedestrians

or children are not likely to touch the generator.

9 Avoid placing any flammable materials near the exhaust outlet during operation.

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741-086

a

9 Keep the generator at least 1 m (3 ft) from build- ings or other equipment, or the engine may over- heat.

a 1 m (3 ft)

5

741-087

741-088

741-089

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741-077

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AE01020

ELECTRIC SHOCK PREVENTION 9 Never operate the engine in rain or snow.

9 Avoid operating the engine with a dust cover.

9 Be sure to carry the generator only by its carrying handle.

1 Carrying handle

9 Never touch the generator with wet hands or elec- trical shock will occur.

9 Be sure to ground (earth) the generator. NOTE: Use ground (earth) lead of sufficient current capacity.

1 Lead diameter

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1

2

1

2

741-090

AE00088

CONNECTION NOTES 9 Avoid connecting the generator to commercial

power outlet. 9 Avoid connecting the generator in parallel with any

other generator.

1 Correct 2 Incorrect

AE00091

CONNECTION

w Before the generator can be connected to a build- ings electrical system, a licensed electrician must install an isolation (transfer) switch in the build- ings 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 build- ing electrical system damage can occur when nor- mal operating power returns if unit is used without an isolation switch.

AE00086

EXTENSION CORD NOTES 9 When using an extension cord, its total length

should not exceed 60 meters for cross section of 1.5 mm square and 100 meters for cross section of 2.5 mm square.

9 This extension cord should be protected by a tough flexible rubber sheath (IEC 245) or the equivalent to withstand mechanical stresses.

6

Ground (earth) Lead Diameter:

0.12 mm (0.005 in)/ampere EX;

10 Ampere 1.2mm (0.05 in)

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AE00101

CONTROL FUNCTION

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AE00103

CONTROL PANEL 1 Overload indicator light 2 AC pilot light 3 Oil warning light 4 Engine switch (Red) 5 Choke knob 6 Fuel cock knob 7 Ground (Earth) terminal 8 Economy control switch (Black) 9 DC protector 0 AC receptacle q DC receptacle

AE00102

DESCRIPTION 1 Fuel tank 2 Fuel tank cap 3 Fuel tank cap air vent knob 4 Fuel cock knob 5 Air filter cover 6 Spark plug 7 Muffler 8 Choke knob 9 Ground (Earth) terminal 0 Oil filler cap q Recoil starter w Carrying handle

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AE00111

OIL WARNING SYSTEM When the oil level falls below the lower level, the engine stops automatically. Unless you refill with oil, the engine will not start again.

NOTE: If the engine stalls or does not start, turn the engine switch to "ON" position and then pull the recoil starter. If the oil warning light flickers for a few seconds, the engine oil is insufficient. Add oil and restart.

8

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AE00939

ENGINE SWITCH (Red) The engine switch controls the ignition system. 1 7 ON Ignition circuit is switched on. The engine can be started. 2 5 STOP Ignition circuit is switched off. The engine will not run. AE00988

ECONOMY CONTROL SWITCH (Black) 1 I ON When the economy control switch is turned I, the economy control unit controls the engine speed according to the connected load. The results are better fuel consumption and less noise.

2 3 OFF When the economy control switch is turned 3, the engine runs at the rated r/min (5,000 r/min) regardless of whether there is a load connected or not.

NOTE: The economy control switch must be turned to 3 (OFF) when using electric devices that require a large starting current, such as a compressor or a submergi- ble pump.

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AE01099

DC PROTECTOR The DC protector turns off automatically when the load exceeds the generator rated output.

cC Reduce the load to the specified generator rated output if the DC protector turns off. If it turns off again, consult a Yamaha dealer.

NOTE: Press to reset the DC protector.

1 RESET 2 OFF

9

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AE01021

FUEL TANK CAP AIR VENT KNOB The fuel tank cap is provided with an air vent knob to stop fuel flow. The air vent knob must be turned 1 turn counterclock- wise from the tightened position. This will allow fuel to flow to the carburetor and the engine to run. When the engine is not in use, tighten the air vent knob clockwise until it is finger-tight to stop fuel flow.

1 Air vent knob 2 Fuel tank cap

763-227

q

707-098

OFF

ON

AE01034

FUEL COCK KNOB The fuel cock knob is used to supply fuel from the fuel tank to the carburetor.

Remove the cover 1 and the fuel cock lever can be found inside. If for some reason the fuel cock knob cannot be turned, this lever can be used to supply fuel.

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741-091

707-092

707-095

AE00845

PRE-OPERATION CHECK

NOTE: Pre-operation checks should be made each time the generator is used.

w The engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or repair.

AE00212

FUEL Make sure there is sufficient fuel in the tank.

Your Yamaha engine has been designed to use regu- lar unleaded gasoline with a pump octane number ((R + M)/2) of 86 or higher, or research octane number of 91 or higher.

w 9 Fuel is highly flammable and poisonous.

Check SAFETY INFORMATION (See page 4) carefully before refueling.

9 Do not fill above the top of the fuel filter or it may overflow when the fuel heats up later and expands.

9 Wipe up any spilled fuel immediately. 9 After refueling, make sure the tank cap is tight-

ened securely.

10

707-091

Recommended fuel: Unleaded gasoline

Fuel tank capacity: Total: 2.5 L (0.55 Imp gal, 0.66 US gal)

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700-116

700-119

1

741-079

AE01158

ENGINE OIL Make sure the engine oil is at the upper level of the oil filler hole. Add oil as necessary.

NOTE: Place the generator on a level surface and check the oil level of the oil filler hole.

1 Upper level

NOTE: Recommended engine oil classification: API Service SE or SF.

2 Oil filler guide

cC 9 The generator has been shipped without

engine oil. Fill with oil or it will not start. 9 Do not tilt the generator when adding engine

oil. This could result in overfilling and damage to the engine.

11

700-065

0C 25C

80F32F

A YAMALUBE 4(10W-30)

D SAE 10W C SAE #20 B SAE #30

700-1262

Recommended oil: YAMALUBE 4 (10W-30) or SAE 10W-30

type SE motor oil SAE #30 SAE #20 SAE 10W

Engine oil quantity: 0.32 L (0.28 lmp qt, 0.34 US qt)

AE00241

GROUND (Earth)

Make sure to ground (earth) the generator. Check SAFETY INFORMATION on page 5.

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12

AE01109

OPERATION

cC 9 The generator has been shipped without

engine oil. Fill with oil or it will not start. 9 Do not tilt the generator when adding engine

oil. This could result in overfilling and damage to the engine.

1 Upper level

AE01104

STARTING THE ENGINE

NOTE: 9 Before starting the engine, do not connect any

electric devices. 9 Turn the economy control switch (Black) to the

3 (OFF) position.

1 3 OFF

3. Turn the engine switch (Red) to the 7 (ON) posi- tion.

1 7 ON

2. Turn the fuel cock knob to the ON position.

1 ON

1. While holding the fuel tank cap so that it will not move, turn the air vent knob 1 turn counterclock- wise to open the fuel tank air vent.

1 Air vent knob

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700-127

705-071c

qON

OFF

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13

7. Push the choke knob back to the original position.

4. Pull the choke knob fully out.

1 Choke knob

NOTE: The choke is not required to start a warm engine. Push the choke knob in to the original position.

5. Pull slowly on the recoil starter until it is engaged, then pull it briskly.

NOTE: Grasp the carrying handle firmly to prevent the gener- ator from falling over when pulling the recoil starter.

6. After the engine starts, warm up the engine until the engine does not stop when the choke knob is returned to the original position.

701-049c

704-017

701-049b

q

NOTE: When starting the engine, with the economy control switch I (ON), and there is no load on the generator: 9 in ambient temperature below 3C (37F), the

engine will run at the rated r/min (5,000 r/min) for 5 minutes to warm up the engine.

9 in ambient temperature above 3C (37F), the engine will run at the 4,000 r/min for 3 minutes to warm up the engine.

The economy control unit operates normally after the above time period, while the economy control switch is I (ON).

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NOTE: 9 means below. 9 Application wattage indicates when each device is

used by itself. 9 The simultaneous usage of AC and DC power is

possible but total wattage should not exceed the rated output. EX:

9 The overload indicator light 1 comes on when total wattage exceeds the application range. (See page 16 for more details.)

14

AE01000

APPLICATION RANGE

AC DC

Power factor 1 0.80.95 0.40.75

(Efficiency 0.85)

EF1000iS 900W 720W 300W

Rated voltage 12V

Rated current 8A

763-225

q Generator rated output 900VA

Frequency Power factor

1.0 800W AC

0.8 640W 96W

DC (12V/8A)

cC Be sure the total load is within generator rated output otherwise generator dam- age will occur.

NOTE: Some precision equipment is voltage sensitive and may require a more uniform voltage supply than portable generators provide. Examples include some medical equipment, personal computers, and some inverters that sense peak and RMS voltage values. Consult the precision-equipment vendor before relying on any portable generator to pro- vide power to such equipment.

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AE01023

CONNECTION

Alternating Current (AC)

cC 9 Be sure all electric devices including the lines

and plug connections are in good condition before connection to the generator.

9 Be sure any electric devices are turned off before plugging it in.

9 Be sure the total load is within generator rated output.

9 Be sure the receptacle load current is within receptacle rated current.

1. Wind the power lead 2 or 3 turns around handle. 2. Start the engine. 3. Plug in to the AC receptacle.

4. Make sure the AC pilot light is on.

1 AC pilot light

5. Turn the economy control switch (Black) to the I (ON) position and turn on any electric devices.

1 I (ON)

NOTE: The economy control switch must be turned to 3 (OFF) when using electric devices that require a large starting current, such as a compressor or a submergi- ble pump.

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763-225

q AE00953

Overload indicator light The overload indicator light 1 comes on when an overload of a connected electrical device is detected, the inverter control unit overheats, or the AC output voltage rises. The electronic breaker will then activate, stopping power generation in order to protect the gen- erator and any connected electric devices. The AC pilot light (green) will go off and the overload indicator light (red) will stay on, but the engine will not stop run- ning.

When the overload indicator light comes on and power generation stops, proceed as follows: 1. Turn off any connected electric devices and stop

the engine. 2. Reduce the total wattage of connected electric

devices within the application range. 3. Check for blockages in the cooling air inlet and

around the control unit. If any blockages are found, remove.

4. After checking, restart the engine.

NOTE: 9 The generator AC output automatically resets

when the engine is stopped and then restarted. 9 The overload indicator light may come on for a

few seconds at first when using electric devices that require a large starting current, such as a compressor or a submergible pump. However, this is not a malfunction.

16

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AE01100

Battery Charging NOTE: The generator DC rated voltage is 12V.

1. Wind the battery charging lead 2 or 3 turns around the handle and plug into DC receptacle.

NOTE: 9 Make connections to the battery after starting the

engine. 9 Clamp the red wire to the positive (+) terminal and

the black wire to the negative (-) terminal of the battery. Do not reverse these positions.

1 Red 2 Black

2. Start the engine. 3. Press in the DC protector and install the battery.

cC 9 Be sure the economy control switch is turned

off while charging the battery. 9 Be sure the battery leads are properly con-

nected. 9 Be sure the breather hose is properly connect-

ed and is not damaged or obstructed. 9 Reduce the load to the specified generator

rated output if the DC protector turns off. If it turns off again, consult a Yamaha dealer.

NOTE: Press to reset the DC protector.

1 RESET 2 OFF

NOTE: 9 At full charge, electrolyte specific gravity is

between 1.26 and 1.28. 9 Check specific gravity hourly.

17

761-079a

762-040

12

6v 6v 12v 762-041

763-238a

q

w

7CG-28199-10 4/1/04 3:13 PM Page 17

762-012

w Never smoke or make and break connections at the battery while charging. Sparks may ignite the battery gas. Battery electrolyte is poisonous and dangerous, causing severe burns, etc. contains sulfuric (sul- phuric) acid. Avoid contact with skin, eyes or clothing. Antidote: EXTERNAL-Flush with water. INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or veg- etable oil. Call physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explo- sive gases. Keep sparks, flame, cigarettes, etc., away. Ventilate when charging or using in closed space. Always cover eyes when working near bat- teries. KEEP OUT OF REACH OF CHILDREN.

18

7CG-28199-10 4/1/04 3:13 PM Page 18

19

763-222

q

761-078

763-223a

q

705-071d

q

ON

OFF

707-097a

AE01025

STOPPING THE ENGINE

NOTE: 9 Turn off any electric devices. 9 Turn the economy control switch (Black) to the

3 (OFF) position.

1 3 OFF

1. Disconnect any electric devices.

3. Turn the fuel cock knob to OFF.

1 OFF

4. Turn the fuel tank cap air vent knob clockwise until it is finger-tight.

2. Turn the engine switch (Red) to the 5 (STOP) position.

1 5 STOP

7CG-28199-10 4/1/04 3:13 PM Page 19

20

AE00401

PERIODIC MAINTENANCE AE00403

MAINTENANCE CHART Regular maintenance is most important for best performance and safe operation.

w Stop the engine before starting maintenance work.

* : It is recommended that these items be serviced by a Yamaha dealer. ** : Related to emission control system.

No. Item Remarks

Pre-Ope- ration check (daily)

Initial Every

1 month

or 20 Hr

3 months or 50 Hr

6 months

or 100 Hr

12 months

or 300 Hr

Check condition.

1. ** Adjust gap and 0Spark Plug

clean. Replace if necessary.

** Check and adjust

2.* Valve Clearance when engine is 0 cold.

Check breather ** hose for cracks or

03.* Crankcase damage. Replacebreather system if necessary.

Check for leakage. Retighten or

0 *replace gasket

** if necessary.

4. Exhaust System Check muffler screen and spark arrester. Clean/ 0 replace if necessary.

Check oil level 0 5. Engine Oil

Replace 0 0

** Clean. 6. Air Filter Replace if 0

necessary.

Clean fuel tank 7. Fuel Filter filter. Replace if 0

necessary.

7CG-28199-10 4/1/04 3:13 PM Page 20

21

* : It is recommended that these items be serviced by a Yamaha dealer. ** : Related to emission control system.

cC Use only Yamaha specified genuine parts for replacement. Ask an authorized Yamaha dealer for further attention.

Check fuel hose

8. Fuel Line for crack or da-

0 mage. *Replace if necessary.

9. ** Check choke 0Choke knob

operation.

10. Cooling System Check for fan

0 damage.

11. Starting System Check recoil

0 starter operation.

12.* ** More frequently

0Decarbonization if necessary.

13. Generation Check the pilot

0 light comes on.

Check all fittings

14.* Fittings/ and fasteners.

0 Fasteners Correct if

necessary.

No. Item Remarks

Pre-Ope- ration check (daily)

Initial Every

1 month

or 20 Hr

3 months or 50 Hr

6 months

or 100 Hr

12 months

or 300 Hr

7CG-28199-10 4/1/04 3:13 PM Page 21

22

760-024

760-025q

2. Check for discoloration and remove the carbon.

3. Check the spark plug type and gap.

a Gap

4. Install the spark plug.

5. Install the cover.

a

760-001a

Standard electrode color: Tan Color

Standard Spark Plug: CR4HSB (NGK)

Spark Plug Gap: 0.60.7 mm (0.0240.028 in)

Spark Plug Torque: 12.5 Nm (1.25 kgfm, 9 lbfft)

AE00431

CARBURETOR ADJUSTMENT The carburetor is a vital part of the engine. Adjusting should be left to a Yamaha dealer with the profession- al knowledge, specialized data, and equipment to do so properly.

AE01026

SPARK PLUG INSPECTION You should periodically remove and inspect the spark plug. 1. Remove the cover 1.

7CG-28199-10 4/1/04 3:13 PM Page 22

7. Add engine oil to the upper level of the filler hole using the oil filler guide.

6 Oil filler guide

cC Do not tilt the generator when adding engine oil. This could result in overfilling and damage to the engine.

23

3

4

700-124

700-118b

5

700-120

700-126a6

AE01159

ENGINE OIL REPLACEMENT 1. Place the generator on a level surface and warm

up the engine for several minutes. Then stop the engine and turn the fuel cock knob to OFF. Turn the fuel tank cap air vent knob clockwise.

2. Loosen the screw 1 and remove the cover 2. 3. Remove the oil drain joint 3 pushing downward

from the bottom of the generator and remove the oil filler cap 4.

4. Attach the oil drain joint 5 to the oil filler hole.

788-009

q

w

5. Place an oil pan under the engine. Tilt the genera- tor to drain the oil completely.

6. Replace the generator on a level surface and remove the oil drain joint.

700-065

0C 25C

80F32F

A YAMALUBE 4(10W-30)

D SAE 10W C SAE #20 B SAE #30

Recommended oil: YAMALUBE 4 (10W-30) or SAE 10W-30

type SE motor oil SAE #30 SAE #20 SAE 10W

Engine oil quantity: 0.32 L (0.28 lmp qt, 0.34 US qt)

7CG-28199-10 4/1/04 3:13 PM Page 23

24

NOTE: Recommended engine oil classification: API Service SE or SF.

711-068

q

711-069

3

2

AE01028

MUFFLER SCREEN AND SPARK ARRESTER

w The engine and muffler will be very hot after the engine has been run. Avoid touching the engine and muffler while they are still hot with any part of your body or clothing during inspection or repair.

1. Remove the cover 1.

741-091

2. Remove the muffler screen.

2 Muffler screen 3 Screw

700-117a

788-010

8. Wipe the oil drain joint clean, and wipe up any spilled oil.

cC Be sure no foreign material enters the crankcase.

9. Install the oil filler cap. 10. Replace the oil drain joint in its original position. 11. Install the cover and tighten the screw.

7CG-28199-10 4/1/04 3:13 PM Page 24

25

711-050

711-071a2 1

5. Remove the carbon deposits on the muffler screen and spark arrester using a wire brush.

cC When cleaning, use the wire brush lightly to avoid damaging or scratching of the muffler screen and spark arrester.

6. Check the muffler screen and spark arrester. Replace them if damaged.

711-069a

4. Remove the spark arrester.

4 Spark arrester

7. Install the spark arrester.

NOTE: Align the spark arrester projection with the hole in the muffler pipe.

1 Projection

2 Hole

8. Install the muffler screen.

711-070

711-022

3. Use a flathead screw driver to pry the spark arrester out from the muffler.

711-071

4

7CG-28199-10 4/1/04 3:13 PM Page 25

3. Remove the air filter cover and element 4. 4. Wash the element in solvent and dry. 5. Oil the element and squeeze out excess oil.

The element should be wet but not dripping.

cC Do not wring out the element. This could cause it to tear.

6. Insert the element into the air filter. NOTE: Be sure the element sealing surface matches the air filter so there is no air leak.

26

710-059a

r

AE01029

AIR FILTER 1. Remove the cover 1.

2. Remove the clip 2 holding the air filter cover 3.

Recommended oil: Foam-air-filter oil

or SAE #20 motor oil

788-001

q

788-002a

e

w

711-068a

9. Install the cover.

7CG-28199-10 4/1/04 3:13 PM Page 26

27

707-094

q

AE00471

FUEL TANK FILTER 1. Remove the fuel tank cap and filter.

1 Filter

2. Clean the filter with solvent. If damaged, replace. 3. Wipe the filter and insert it.

w Be sure the tank cap is tightened securely.

cC The engine should never run without the element; excessive piston and cylinder wear may result.

w Never use solvent while smoking or in the vicinity of an open flame.

7. Replace the air filter cover in its original position and install the clip.

8. Install the cover.

7CG-28199-10 4/1/04 3:13 PM Page 27

28

707-091

AE01097

TROUBLESHOOTING

Engine wont start 1. Fuel systems

No fuel supplied to combustion chamber. 2 No fuel in tank .... Supply fuel. 2 Fuel in tank .... Fuel tank cap air vent knob to

OPEN (turn it 1 turn counterclockwise). Fuel cock knob to ON.

2 Clogged fuel line .... Clean fuel line. 2 Clogged carburetor .... Clean carburetor.

705-072

ON

OFF

700-006

763-223b

760-009

AE00785

Generator wont produce power 2 Safety device (AC) to OFF .... Stop the engine,

then restart. 2 Safety device (DC protector) to OFF .... Press to

reset the DC protector.

2. Engine oil system Insufficient

2 Oil level is low .... Add engine oil.

3. Electrical systems 2 Engine switch (Red) to ON.

Poor spark 2 Spark plug dirty with carbon or wet .... Remove

carbon or wipe spark plug dry. 2 Faulty ignition system .... Consult dealer.

4. Compression Insufficient

2 Worn out piston and cylinder .... Consult dealer.

7CG-28199-10 4/1/04 3:13 PM Page 28

29

P OK

O Clogged

Engine does not start.

C Does not flicker D Flickers.

B

AE00515

A ENGINE DOES NOT START

Turn the engine switch to ON, then pull the recoil starter and check if the oil warining light flickers.

H Pull the recoil starter and check the spark plug for spark strength. (See WARNING)

w 9 To prevent FIRE HAZARDS be

sure fuel is not present in the spark plug area.

9 To prevent FIRE HAZARDS be sure to place the spark plug as far way as possible from the spark plug hole and carburetor area.

9 To prevent ELECTRIC SHOCK do not hold spark plug lead with hand while testing.

Engine starts.I J

Check the following 9 Fuel line clogging 9 Air cleaner element

clogging.

N Clean or Replace; Consult a Yamaha dealer.

Q

R Consult a Yamaha dealer.

K Check the spark plug. 9 Type: 9 Gap:

L Incorrect M OK

Replace or Adjust Gap.

Clean the spark plug.

E Check engine oil level.

F OK G Level low

Consult a Yamaha dealer.

Add engine oil.

7CG-28199-10 4/1/04 3:13 PM Page 29

30

706-025

788-001

q

707-103

w

712-026

AE00601

STORAGE Long term storage of your machine will require some preventive procedures to guard against deterioration.

AE00621

ENGINE 1. Remove the spark plug, pour about one table-

spoon of SAE 10W30 or 20W40 motor oil into the spark plug hole and reinstall the spark plug. Recoil start the engine by turning over several times (with ignition off) to coat the cylinder walls with oil.

2. Pull the recoil starter until you feel compression. Then stop pulling. (This prevents the cylinder and valves from rusting).

3. Clean exterior of the generator and apply a rust inhibitor.

4. Store the generator in a dry, well-ventilated place, with the cover placed over it.

5. The generator must remain in a vertical position when stored, carried or operated.

AE01095

DRAIN THE FUEL 1. Remove the fuel tank cap. Drain the fuel from the

fuel tank into an approved gasoline container using a commercially available hand siphon. Then, install the fuel tank cap.

w 9 Fuel is highly flammable and poisonous.

Check SAFETY INFORMATION (See page 4) carefully.

9 Wipe up any spilled fuel immediately.

2. Remove the cover 1. Drain fuel from the carburetor by loosening the drain screw 2 on the carburetor float chamber.

3. Turn the fuel cock knob to OFF. Start the engine and leave it run until it stops. This will burn any remaining fuel in the carburetor.

7CG-28199-10 4/1/04 3:13 PM Page 30

31

AE00789

EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS

Item Acronym 9 CARB. ASSY., LH. & JT., .......................CARB (Carburetor)

CARBURETOR2 9 T.C.I. MAGNETO ASSY. & .....................EI (Electronic Ignition)

PLUG, SPARK 9 CRANKCASE1 & HEAD, ........................PCV (Positive Crankcase

CYLINDER1 Ventilation) 9 AIR FILTER ASSY. .................................ACL (Air Cleaner) 9 MUFF., 2, CAP, NET, WIRE2 &

ARRESTER, SPARK

The above items and the corresponding acronyms are provided in accordance with U.S. EPA REGULATIONS FOR NEW NONROAD SPARK-IGNITION NONHANDHELD ENGINES and the CALIFORNIA REGULATIONS FOR 1995 AND LATER SMALL OFF-ROAD ENGINES. The acronyms conform to the latest version of the SAEs recommended prac- tice document J1930, Diagnostic Acronyms, Terms, and Definitions For Electrical/Electronic System.

It is recommended that these items be serviced by a Yamaha dealer.

7CG-28199-10 4/1/04 3:13 PM Page 31

32

Unit EF1000iS Type Forced air cooled 4-stroke gasoline OHV Cylinder Arrangement Vertical 1 cylinder Displacement cm3 50 Bore Stroke mm (in) 41.0 38.0 (1.61 1.50) Rated Output kW(HP)/r/min 1.21 (1.67)/5,000 Operation Hours at rated operation Hr 4.3 Fuel Unleaded gasoline Fuel Tank Capacity L (Imp gal, US gal) 2.5 (0.55, 0.66) Engine Oil Quantity L (Imp qt, US qt) 0.32 (0.28, 0.34) Ignition System TCI

Spark Plug: Type CR4HSB (NGK) Spark Plug: Gap mm (in) 0.60.7 (0.0240.028)

Noise Level* dB (A) 57

Unit EF1000iS AC Output

Rated Voltage V 120 Rated frequency Hz 60 Rated current A 7.5 Rated Output VA 900 Safty Device: Type Electronic

DC Output Rated voltage V 12 Rated current A 8 Safety Device: Type DC protector

Unit EF1000iS Overall Length mm (in) 450 (17.7) Overall Width mm (in) 240 (9.4) Overall Height mm (in) 380 (15.0) Dry Weight kg (lb) 12.7 (28.0)

AE00701

SPECIFICATIONS AE00702

DIMENSIONS

AE00704

ENGINE

AE00707

GENERATOR

* : Measured at rated operation from 7 m (23 ft) distance.

7CG-28199-10 4/1/04 3:13 PM Page 32

33

770-044f

W

W

W

WW

W W

Br Br Br

Br

BrBrBrW W W

Br BrBr

Br Br

W W W

W W W

W W W

R

RR

Br

R

Br

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W W L L

L

L

L Y B

B

B B B

B

B

B

B

B

R

R

R

R LL

L L

GG YY

O

R L

G Y

O

O

B/W

B/W B/W

B/W

B/W

B/W B/W

G/Y

G/Y

B/W

B/W

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YY

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q

r e

w t

@1

@0!7

!8 !6

i !4

!3 !9!5

!2

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u uy

AE00751

WIRING DIAGRAM

1 Main coil 2 Sub coil 3 DC coil 4 DC rectifier 5 Control unit 6 AC pilot light 7 AC receptacle 8 Ground (Earth) terminal 9 Economy control switch 0 Overload indicator light q DC protector (breaker)

w DC receptacle e Engine switch r Oil warning light t Speed limiter y Oil level gauge u Ignition coil i Spark plug o TCI unit p TCI magneto a Stepping motor

Color code B Black Br Brown G Green Gy Gray L Blue O Orange R Red W White Y Yellow B/W Black/White G/Y Green/Yellow

7CG-28199-10 4/1/04 3:13 PM Page 33

7CG-28199-10 hyoshi 3/22/04 4:51 PM Page 2

Generator

LIT-19626-01-19 7CG-28199-10PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 04 904 1.2 1 !