Contents

Yamaha EF12000DE v3 Owner's Manual PDF

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Summary of Content for Yamaha EF12000DE v3 Owner's Manual PDF

Generator

LIT-19626-02-08 7UX-28199-1BPRINTED ON RECYCLED PAPER

PRINTED IN JAPAN 2013.111 !

(E)

EF12000DE

OWNERS MANUAL

Read this manual carefully before operating this machine.

3ZZ9020237 ISSUE EMD-GU7307

7UX-9-1B_hyoshi 13.11.4 10:14 1

7UX-9-1B_hyoshi 13.11.4 10:14 2

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.

EF12000DE OWNERS MANUAL

2013 by Yamaha Motor Corporation, U.S.A. 1st Edition, November 2013

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-19626-02-08

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

Particularly important information is dis- tinguished in this manual by the follow- ing notations.

This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

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

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

TIP

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

*Product and specifications are subject to change without notice.

TIP

9 Yamaha continually seeks advance- ments in product design and quali- ty. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor dis- crepancies between your engine and this manual. If there is any question concerning this manual, 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.

851-005

NOTICE

WARNING

WARNING

IMPORTANT MANUAL INFORMATION

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Check that following acces- sories come with your Yamaha Generator.

(1) Owners manual

(2) Wheel mounting parts (See page 39.)

(3) Servicing tools

(4) Battery mounting bracket (See page 13.)

Be sure to replenish with engine oil. (See page 10 for details.)

The generator has been shipped without engine oil. Do not start the engine until you have filled it with the sufficient engine oil.

NOTICE

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Symbols and Meanings In accordance with the European requirements (eec Directives), the specified symbols as shown in the following table are used for the products and this instruction manual.

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CONTENTS

LOCATION OF IMPORTANT LABELS ..................................................1

SAFETY INFORMATION ........................................................................2

EXHAUST FUMES ARE POISONOUS.............................................3

FUEL IS HIGHLY FLAMMABLE AND POISONOUS .......................3

ENGINE AND MUFFLER MAY BE HOT...........................................4

ELECTRIC SHOCK PREVENTION ..................................................4

CONNECTION NOTES .....................................................................5

CONNECTION...................................................................................5

EXTENSION CORD NOTES .............................................................5

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

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

CHECK ENGINE OIL ......................................................................10

CHECK FUEL..................................................................................11

BATTERY INSTALLATION..............................................................13

CHECK COMPONENT PARTS.......................................................15

CHECK GENERATOR SURROUNDINGS......................................15

OPERATION .........................................................................................16

STARTING THE ENGINE................................................................16

USING ELECTRIC POWER............................................................17

STOPPING THE GENERATOR.......................................................22

WATTAGE INFORMATION ...................................................................23

VOLTAGE DROP IN ELECTRIC EXTENSION CORDS..................24

MAINTENANCE SCHEDULE...............................................................25

DAILY INSPECTION........................................................................25

PERIODICAL MAINTENANCE.......................................................25

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"HOW-TO" MAINTENANCE.................................................................27

ENGINE OIL CHANGE ...................................................................27

ENGINE OIL FILTER REPLACEMENT ..........................................27

SERVICING AIR CLEANER............................................................28

CLEANING AND ADJUSTING SPARK PLUG ...............................29

CLEANING FUEL STRAINER ........................................................29

FUEL HOSE REPLACEMENT........................................................30

CHECKING CARBON BRUSH .......................................................30

BATTERY-Replenishing the battery fluid.....................................31

SPARK ARRESTER .............................................................................32

PREPARATION FOR STORAGE..........................................................33

HIGH ALTITUDE ENGINE OPERATION ........................................34

BATTERY ........................................................................................34

TROUBLESHOOTING..........................................................................35

SPECIFICATIONS ................................................................................36

CONSUMER INFORMATION ...............................................................37

WIRING DIAGRAM...............................................................................38

OPTIONAL PARTS...............................................................................39

"HOW-TO" INSTALL THE WHEEL.................................................39

YAMAHA EXTENDED SERVICE (Y.E.S.) ............................................40

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1

1

2

2 6

5

4

3

7

REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. THIS ENGINE MEETS EMISSION STANDARDS FOR ****U.S. EPA REGULATIONS FOR SMALL NON-ROAD ENGINES (EMISSION COMPLIANCE PERIOD OF 1000 HOURS) AND **** CALIFORNIA SI SORE's. YAMAHA MOTOR POWERED PRODUCTS CO.,LTD.

ENGINE FAMILY- DISPLACEMENT 653 cm3 IMPORTANT ENGINE INFORMATION EM

EH63 .64 .65

*****.****** 4

5

3

DANGER Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home or garage, EVEN IF doors and windows are open.

Only use OUTSIDE and far away from windows, door, and vents.

7CG-24877-00

1

6

7

LOCATION OF IMPORTANT LABELS Please read the following labels carefully before operating this machine.

TIP

Maintain or replace safety and instruction labels, as necessary.

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2

1

G-380

SAFETY INFORMATION

9 This generator is not designed for on-board use. Do not use it while installed on the vehi- cle.

9 Do not modify the generator or use it with its parts removed.

9 Do not allow children to operate the generator.

9 Be sure to carry the generator only by its carry- ing handle(s).

1 Carrying handle(s) (shaded)

9 Do not place any obstacles on the generator.

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3

743-003

743-005

743-004

G-382

FUEL IS HIGHLY FLAMMABLE AND POISO- NOUS 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 Do not leave the generator inside the vehicle or

in the trunk. 9 If you swallow any fuel, inhale fuel vapor, or

allow any to get in your eye(s), see your doctor immediately. 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 machine, be sure it is kept upright. If it tilts, fuel may leak from the carburetor or fuel tank.

743-002

G-381

EXHAUST FUMES ARE POISONOUS 9 Using a generator indoors CAN KILL YOU IN

MINUTES. Generator exhaust contains car- bon monoxide. This is a poison you cannot see or smell.

9 NEVER use inside a home or garage, EVEN IF doors and windows are open.

9 Only use OUTSIDE and far away from win- dows, doors, and vents.

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743-008K

743-009

743-010

743-011

9 In order to prevent overheating, ensure adequate airflow by keeping the machine at least 1 m (3 ft) from objects or other equipment.

9 Do not operate the engine with a dust cover or other objects covering it.

9 When covering the generator, be sure to do so only after the engine and muffler have com- pletely cooled down.

G-384

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

9 Never touch the machine with wet hands or electrical shock will occur.

4

743-006

743-007

G-383

ENGINE AND MUFFLER MAY BE HOT 9 Place the machine in a place where pedestri-

ans or children are not likely to touch the machine.

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

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743-013

q

w

q

w

G-385

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

G-440

CONNECTION

G-387

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.

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.

WARNING

1 9 Connect the Ground (earth) terminal to a ground source. In order to prevent electrical shock, the generator must be grounded when using an electrical device with a ground plug.

1 Ground (earth) terminal

5

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Notes on installation 1. If you provide the generator with wheels, always be sure to place the genera-

tor on a level surface, locking the wheel with the stopper and / or chocking the wheels.

2. Select a place that allows you to maintain and inspect the generator, which is not exposed to contamination by exhaust gas.

If you are planning to install the generator without its wheels attached, take into consideration being able to make oil changes efficiently.

3. In ground connection, be sure to use the designated ground terminal.

(A grounding cable is not included in the set of accessories.)

4. During use, be sure not to disconnect the battery.

5. While the power is on, do not unplug the unit or disconnect cables from the terminals.

6

Warning labels are affixed to our engines with regard to particularly serious dangers. When using the engines, please use them safely after carefully reading the instruction manual and understanding the dangers.

WARNING : PRECAUTIONS ON THE HANDLING OF THE WARNING LABEL

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CONTROL FUNCTION

TANK CAP FUEL TANK

AIR CLEANER

SPARK PLUG CAP

FUEL COCK

CONTROL PANEL

BATTERY

STOPPER

MUFFLER

CONNECTOR FOR REMOTE CONTROL

SPARK PLUG CAP

OIL FILLER CAP

OIL GAUGE

ELECTRIC STARTER

OIL DRAIN PLUG

OIL FILTER

FUEL GAUGE

7

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Automatic bulb checking When the starter switch is turned to the "START" from the "STOP" position, the oil pressure warning lamp flashes only once to check the bulb.

If it does not flash, ask a Yamaha dealer to inspect the electrical circuit.

Fail-safe Function of ECU (Electronic Control Unit) When the remote control unit is connected, the engine will not start unless

both starter switch on the control panel and the engine switch on the remote control unit are switched on.

If the engine does not run for 3 seconds when the starter switch is turned to the "START" position on either the generator or the remote control unit, the starter motor will stop automatically.

If the engine does not start for 21 seconds when the starter switch is turned to the "START" position on either the generator or the remote control unit, the starter motor will stop automatically.

TIP

If the engine stalls, check the engine oil level or contamination. Add or change oil, and restart. (See page 10 for more details.) Check the fuel level and the fuel cock because the same result can be expect- ed when the fuel runs out.

If the engine runs over 4500 r/min for 7 seconds, the engine stops automatical- ly and the oil pressure warning lamp flashes for 3 minutes.

Oil Pressure Monitoring System The engine is equipped with an oil pressure sensor (of a hydraulic pressure detection type).

If this sensor detects the oil pressure below the specified level, it stops the engine automatically. Then, the oil pressure warning lamp flashes for 3 minutes and goes off.

9

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PRE-OPERATION CHECK

UPPER LEVEL

LOWER LEVEL

OIL GAUGE

OIL GAUGE

UPPER LEVEL

LOWER LEVEL

CHECK ENGINE OIL Before checking or refilling oil, be sure gener- ator is located on stable and level surface with engine stopped.

1) Remove oil level gauge and check the engine oil level.

2) If oil level is below the lower level line on the oil gauge, refill with suitable oil (see table) to upper level after removing the engine oil filler cap.

3) Change oil if contaminated. (See "How-To" Maintenance.)

Oil capacity1.55 L (1.64 US qt, 1.36 Imp qt)

TIP The engine is equipped with an oil sensor

unit (hydraulic pressure detection type) that will automatically stop the engine if oil in the crank case is reduced below the specified level. Should the engine be automatically stopped, be sure to check the amounts of fuel and oil.

When the oil is reduced below the specified level, add new oil to the upper limit. Since the oil sensor will not detect the deteriora- tion of oil, visually check the quality or determine it by the specified time and then change the oil if necessary. (Refer to page 27.)

OIL FILLER CAP

0C

YAMALUBE 4 (10W-40)

SAE 10W SAE #20 SAE #30

32F

25C

80F

Recommended engine oil: YAMALUBE 4 (10W-40),

SAE 10W-30 or 10W-40 SAE #30 SAE #20 SAE 10W

Recommended engine oil grade: API Service SE type or higher

10

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1) Check fuel level at fuel level gauge.

2) If fuel level is low, refill with unleaded automotive gasoline.

This engine is certified to operate on automotive unleaded gasoline.

3) Use unleaded automotive gasoline only.

Unleaded regular/premium or refor- mulated gasoline containing no more than 10% Ethanol (E10), or 15% MTBE may also be used.

Never use gasoline containing ethanol exceeding 10%, or MTBE exceeding 15% because engine or fuel system damage could result.

Never use stale or contaminated gasoline.

Use of these non-recommended fuels may result in reduced performance and/or denial of warranty.

4) Stop the engine and open the cap.

5) Close the fuel valve before filling the fuel tank.

6) Be sure the fuel filter screen is inserted.

7) Reattach the fuel cap by turning clock- wise until reaching the physical stop (about one quarter turn). Do not attempt to turn past the physical stop or the fuel cap may be damaged.

Fuel filter screen Tank cap

Fuel gauge

CHECK FUEL

Do not refuel while smoking or near open flame or other such potential fire hazards. Otherwise fire accident may occur.

WARNING

11

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Fuel Amount up to "LEVEL" position 38 L (10.04 US gal, 8.36 Imp gal)

EMPTY FULL

E F

TIP

The full level of fuel is the upper surface of the fuel filter.

Be sure to add the fuel in small amounts as the fuel level approaches to the full fuel level mark.

"LEVEL" MARK

FUEL LEVEL LINE Continuous operation time in

normal use (rated load)

60 Hz Approx. 7.1 hours

Make sure you review each warning in order to prevent fire hazard. Do not refill tank while engine is running or hot. Close fuel cock before refueling with fuel. Be careful not to admit dust, dirt, water or other foreign objects into fuel. Do not fill above the top of the fuel filter (marked "LEVEL") or the fuel may

overflow when it heats up later and expands. Wipe off spilt fuel thoroughly before starting engine. Keep open flames away.

WARNING

12

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13

Installation

1) Turn the starter switch to the "STOP" position to prevent accidental short circuit- ing.

2) Attach terminals to a lead-acid battery already charged. Mount the battery onto the position as specified below, with its terminals facing inward.

3) Insert each long bolt through the specified hole, its tip pointing outward.

4) Put the supporting arm on the long bolts and tighten with the butterfly nuts. (Push the lead-acid battery all the way inward.)

5) Arrange the wiring so that it wont be damaged by possible vibration caused by the engine.

6) Only after checking that the engines starter key is in the "STOP" position, securely connect the cable with a red, to the positive (+) terminal first. And then connect the other cable to the negative (-) terminal.

AE00231

BATTERY (See page 31 for more details) Check the fluid level and fill if necessary. Use only distilled water if refilling is necessary.

Recommended Battery Lead-acid battery : A capacity of 12V-32Ah or larger.

For the generators used in low temperature below -5C(23F), 12V-40Ah or larger battery is recommended.

Should the connection be made in incorrect manner, the engine will be dam- aged.

NOTICE

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RED CABLE

RED CABLE

LESS THAN 260 mm (10.2 in)

LESS THAN 170 mm (6.7 in)

LESS THAN 205 mm (8.1 in)

Butterfly nut Long bolt Accessory Supporting arm parts Terminals and nut

Red cable: to the positive (+) terminal

Black cable: to the negative () terminal

14

7UX-9-1B 13.11.4 13:37 14

15

CHECK COMPONENT PARTS Check following items before starting engine:

Fuel leakage from fuel hose, etc. Bolts and nuts for looseness. Components for damage or breakage. Generator not resting on or against any adjacent wiring.

CHECK GENERATOR SURROUNDINGS

Make sure you review each warning in order to prevent fire hazard. Keep area clear of inflammables or other hazardous materials. Keep generator at least 1 meter (3 feet) away from buildings or other struc-

tures. Only operate generator in a dry, well ventilated area. Keep exhaust pipe clear of foreign objects. Keep generator away from open flame. No smoking! Keep generator on a stable and level surface. Do not block generator air vents with paper or other material.

WARNING

7UX-9-1B 13.11.4 13:37 15

16

OPERATION

(3) Turn the starter switch to the "START"

position.

Take your hand off the switch immedi- ately after the engine starts.

If the engine fails to start, release the switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the bat- tery. Do not crank the engine more than 10 seconds on any one attempt.

TIP

A fail-safe function equipped on this gen- erator prevents the starter from cranking the engine within 0.5 second after the engine has been stopped.

STARTING THE ENGINE

CLOSE

CLOSE

OPEN

(1) Make sure that the economy switch and AC switch (no-fuse breaker) are off.

(2) Turn the fuel cock lever to the vertical (open) position.

STOP ON

START

ON

OFF

ECONOMY

SW AC SW

ON

OFF

ON

OFF

Check the oil level before each operations. (See page 10) Perform the specified daily inspection to see if it is in normal condition.

NOTICE

7UX-9-1B 13.11.4 13:37 16

In the following occasion, two or three trials may be required for starting the engine :

(1) The very first starting of a new generator.

(2) After the refueling of the engine which has been stopped due to fuel short- age.

(3) Starting after the oil filter change.

USING ELECTRIC POWER CONTROL PANEL

STOP ON

START

AC

ECONOMY SW

HOUR METER

ECONOMY SWITCH

OIL PRESSURE WARNING LAMP

PILOT LAMP

VOLTAGE METER

AC RECEPTACLE EARTH (GROUND) TERMINAL

STARTER SWITCH

AC SWITCH NO-FUSE BREAKER

20 A 20 A 30 A30 A 50 A

ON

OFF

ON

OFF

AC SW

120V 120 / 240V

ON

OFF

Make sure that the appliance is switched OFF before connecting it to the generator.

Do not move the generator while it is running.

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

Clean dusts, dirt or water off the receptacle before use.

WARNING

17

7UX-9-1B 13.11.4 13:37 17

ON

OFF

ECONOMY

SW AC SW

ON

OFF

ON

OFF

(1) AC APPLICATION

(a) Ground the generator, using the ground terminal located at the side of the panel.

1 Ground (Earth) terminal

(b) Before starting the engine, check that the economy switch and AC switch of the generator and the power switches of the appliances are turned off.

(c) Connect the plugs of the appliances to the receptacles before starting the engine.

(d) Start the engine and check that the voltage meter indicates the rated volt- age.

1

18

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TABLE 1

TWIST

up to 30A

up to 30A

up to 20A NEMA 5-20R

NEMA L5-30R

NEMA L14-30R

NEMA 5-20P

NEMA L5-30P

NEMA L14-30P

G.F.C.I. (Ground Fault Circuit Interrupter) Receptacle, duplex (REC1)

Locking Receptacle (REC2)

Locking Receptacle (REC3)

Style Ampere Receptacle AC plug Description

up to 50A HUBBELL CS6369

HUBBELL CS6365C

Locking Receptacle (REC4)

To take power out from the TWIST LOCK RECEPTACLE, insert the plug into the receptacle, and turn it clock- wise to the lock position.

Be sure to ground the generator if the connected electrical device Is grounded.

The duplex 120V receptacle is protected by a G.F.C.I. (Ground Fault Circuit Interrupter). G.F.C.I. shuts off the output current from the duplex 120V recep- tacle when a ground fault occurs in the generator or the appliance. Please note that other receptacles are not protected by G.F.C.I..

WARNING

NOTICE

19

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(e) Turn the AC switch (no fuse breaker) to on and check to see that the pilot lamp is on.

(f) Turn on the switch of the appliance.

AC SW

ON

OFF

ON

OFF

TIP

The AC switch (no-fuse breaker) turns off automatically when the load exceeds the generator rated output.

When the AC switch (no-fuse breaker) turns off during operation, the genera- tor is over loaded or the appliance is defective. Stop the generator immedi- ately, check the appliance and / or gen- erator for overloading or detect and have repaired as necessary by Yamaha dealer or service shop.

G.F.C.I. RECEPTACLE TEST

After starting the engine, check the G.F.C.I. for proper function- ing by the following test procedure.

Push yellow TEST button, the red RESET button will pop out exposing the word TRIP. Power is now off at the outlets protected by the G.F.C.I., indicating that the device is func- tioning properly.

If TRIP dose not appear when testing, do not use the gen- erator. Call a qualified electrician.

To restore power, push RESET button.

If the RESET button pops out during operation, stop the generator immedi- ately and call a qualified electrician for checking generator and the appli- ances.

WARNING

NOTICE

20

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ECONOMY SWITCH

ECONOMY SWITCH automatically reduces engine speed when load is OFF, and automatically increases engine speed to rated r/min when load is ON. ECONOMY SWITCH provides fuel economy and low noise operation at no-load running.

(1) HOW TO USE ECONOMY SWITCH

Start the engine with ECONOMY SWITCH off.

ON

OFF

ECONOMY

SW

(2) CHECKING THE OPERATION

When ECONOMY SWITCH does not operate normally, please check following :

Overloaded ? Please make it sure that the generator is not overload.

TIP

The ECONOMY SWITCH must be turned to "OFF" to increase engine speed to rated r/min when using a load of 0.04A or less.

The ECONOMY idling speed is 2,400 2,700 r/min.

TIP

Most induction loads such as electric motors require three to five times more wattage than their ratings during starting. This starting wattage should not exceed the rated output of the generator for prop- er operation of ECONOMY SWITCH.

Turn ECONOMY SWITCH off when the ECONOMY SWITCH does not work normally under the rated output.

TIP

Warm up the engine without a load for a few minutes.

Turn ECONOMY SWITCH on.

21

7UX-9-1B 13.11.4 13:37 21

STOPPING THE GENERATOR (1) Turn off the power switch of the elec-

tric equipment.

(2) Turn the economy switch and AC switch (no-fuse breaker) to off.

(3) Unplug the cord from receptacle of the generator.

CLOSE

CLOSE

OPEN

(4) Allow the engine to run at no-load for about 3 minutes to cool down before stopping.

(5) Turn the starter switch to the STOP position.

(6) Close the fuel cock.

STOP ON

START

TIP

It is normal that the engine speed goes up for a moment when you turn the starter switch to "STOP" while the Economy switch is in the "ON" position.

ON

OFF

ECONOMY

SW AC SW

ON

OFF

ON

OFF

22

7UX-9-1B 13.11.4 13:37 22

Some appliances need a "surge" of energy when starting. This means that the amount of electrical power needed to start the appliance may exceed the amount needed to maintain its use. Electrical appliances and tools normally come with a label indicating voltage, cycles/Hz, amperage (amps) and electrical power needed to run the appliance or tool. Check with your nearest dealer or service center with questions regarding power surge of certain appliances or power tools.

Electrical loads such as incandescent lamps and hot plates require the same wattage to start as is needed to maintain use.

Loads such as fluorescent lamps require 1.2 to 2 times the indicated wattage during start-up.

Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.

Electrical motors require a large starting current. Power requirements depend on the type of motor and its use. Once enough "surge" is attained to start the motor, the appliance will require only 50% to 30% of the wattage to continue running.

Most electrical tools require 1.2 to 3 times their wattage for running under load during use. (For example, a 9,000 watt generator can power a 3,200 to 7,000 watt electrical tool.)

Loads such as submersible pumps, air conditioners and air compressors require a very large force to start. They need 3 to 5 times the normal running wattage in order to start. (For example, a 5,000 watt generator would only be able to drive a 1,800 to 3,100 watt pump.)

If the power consumption of electrical appliances exceeds the operating range or if there is short circuit or other problems in the appliances, the AC breaker could trip "OFF" or the rotation of the generator could be abnormally reduced. In this case, stop the generator to see if the power consumption of the appli- ances is too large and if there is a problem in the appliances.

The frequency (the number of the generators rotation) was adjusted before the time of shipment. Changing the frequency could result in the generators break- down, so refrain from changing it.

WATTAGE INFORMATION

23

7UX-9-1B 13.11.4 13:37 23

To determine the total wattage required to run a particular electrical appliance or tool, multiply the voltage figure of the appliance/tool by the amperage (amps) fig- ure of same. The voltage and amperage (amps) information can be found on a name plate which is normally attached to electrical appliances and tools.

VOLTAGE DROP IN ELECTRIC EXTENSION CORDS When a long electric extension cord is used to connect an appliance or tool with the generator, a certain amount of voltage drop occurs in the extension cord which lessens the effective voltage available to the appliance or tool. The chart below has been prepared to illustrate the approximate voltage loss when an extension cord of 300 feet (approx. 100 meters) is used to connect an appliance or tool to the generator.

Applications Applicable Wattage (W)

60 Hz

Incandescent lamp, Heater 9,500

Fluorescent lamp, Electric tool 4,700

Pump, Compressor 2,400

Nominal cross

section

A.W.G. Gauge

No.

Allowable current

No.of strands / strands dia.

Resistance Current Amp.

No./mm /100mmm2 No. A 1A 3A 5A 8A 10A 12A 15A

0.75 18 7 30/0.18 2.477 2.5V 8V 12.5V

V o

lt ag

e d

ro p

1.27 16 12 50/0.16 1.486 1.5V 5V 7.5V 12V 15V 18V

2.0 14 17 37/0.26 0.952 1V 3V 5V 8V 10V 12V 15V

3.5 12 to 10 23 45/0.32 0.517 1.5V 2.5V 4V 5V 6.5V 7.5V

5.5 10 to 8 35 70/0.32 0.332 1V 2V 2.5V 3.5V 4V 5V

TIP

The above wattage chart is general guide only. Refer to your specific appliance for correct wattage.

When you use two or more alternating current outlets at a time, be careful that the sum of the appliances power consumption does not exceed the value speci- fied in the above chart.

24

7UX-9-1B 13.11.4 13:37 24

MAINTENANCE SCHEDULE

DAILY INSPECTION Before running the generator, check the following service items:

Excessive vibration, noise

Clean air cleaner element

Safe surroundings

Enough clean engine oil

Leakage of gasoline and engine oil

Loose or broken bolts and nuts

Enough gasoline

PERIODIC MAINTENANCE Periodic maintenance is vital to safe and efficient operation of your generator. Check the table below for periodic maintenance intervals. IT IS ALSO NECESSARY FOR THE USER OF THIS GENERATOR TO CONDUCT THE MAINTENANCE AND ADJUSTMENTS ON THE EMISSION- RELATED PARTS LISTED BELOW TO KEEP THE EMISSION CONTROL SYS- TEM EFFECTIVE.

The emission control system consists of the following parts :

The maintenance schedule indicated in the table is based on the normal generator operation. Should the generator be operated in extremely dusty condition or in heavier loading condition, the maintenance intervals must be shortened depending on the contamination of oil, clogging of filter elements, wear of parts, and so on.

(1) Carburetor and internal parts

(2) Cold start enrichment system, if applicable

(3) Intake manifold, if applicable

(4) Air cleaner element

(5) Spark plugs

(6) Magneto or electronic ignition system

(7) Spark advance/retard system, if applicable

(8) Exhaust manifold, if applicable

(9) Hoses, belts, connec- tors, and assemblies

25

7UX-9-1B 13.11.4 13:37 25

*Note 1 : Initial oil change should be performed after first twenty (20) hours of operation. Thereafter change oil every hundred (100) hours. Before changing oil, check for a suitable way to dispose of old oil. Do not pour it down into sewage drains, onto garden soil or into open streams. Your local zoning or environmental regulations will give you more detailed instruc- tions on proper disposal.

*Note 2 : As to the procedures for these items, please refer to the SERVICE MANUAL or consult your nearest Yamaha dealer.

*Note 3 : More frequent oil changing, oil filter replacement and air cleaner service on replacement may be necessary depending on operating conditions. This would include dusty environment, high ambient temperature, heavy engine loading.

Periodic Maintenance Schedule table

Maintenance Items Every 8 hours (Daily)

Every 20

hours

Every 200

hours

Every 500

hours

Every 1000 hours

Every 50

hours

Clean generator and check bolts and nuts (Daily)

Check for leakage from hoses and fitting (Daily)

Check and refill engine oil (Refill daily to upper level)

Change engine oil (*Note 1 and 3) (Initial)

Check battery electrolyte fluid level

Clean spark plug

Clean air cleaner

Clean fuel strainer

Replace air cleaner element (*Note 3)

Clean and adjust spark plug and electrodes

Replace engine oil filter (*Note 1 and 3) (Initial)

Clean and adjust carburetor (*Note 2)

Remove carbon from cylinder head (*Note 2)

Clean engine base (oil pan) (*Note 2)

Check and adjust valve clearance (*Note 2)

Replace spark plug

Replace fuel lines (Every 2 years)

Overhaul engine (*Note 2)

Check and replace carbon brushes

Spark arrester

(Every 100 hours)

(Every 100 hours)

26

7UX-9-1B 13.11.4 13:37 26

"HOW-TO" MAINTENANCE

OIL FILTER

ENGINE OIL CHANGE Initial oil change After 20 hours of operation

Thereafter Every 100 hours of operation

1. When changing oil, stop the engine and remove the drain plug.

2. Install the drain plug before refilling oil.

3. Refer to the recommended oil table on page 10.

4. Always use the best grade and clean oil. Contaminated oil, poor quality oil and shortage of oil cause damage to engine or shorten the engine life.

OIL CAPACITY : 1.55 L (1.64 US qt, 1.36 Imp qt)

ENGINE OIL FILTER REPLACEMENT Initial engine oil filter replacement

should be performed after 20 hours of operation. Thereafter replace the engine oil filter every 200 hours.

When installing a new oil filter, apply oil to O-ring, attach the oil filter in position and tighten 2/3 turns by hand or with wrench after touching the O-ring to the sealing surface of engine.

Run the engine for a minute ; stop the engine and check for oil leakage around the oil filter and recheck the oil level.

OIL DRAIN PLUG (ON BOTH SIDE)

OIL FILLER CAP

To prevent injury, pay attention to the spilled hot engine oil when replacing engine oil filter.

NOTICE

27

7UX-9-1B 13.11.4 13:37 27

AIR CLEANER COVER

KNOB

SERVICING AIR CLEANER A dirty air cleaner element will cause starting difficulty, power loss, engine mal- functions, and shorten engine life extremely.

Always keep the air cleaner element clean. Replace the air cleaner element set more often in dusty environments.

The air cleaner paper inner element and urethane foam outer element can be removed after removing knob and air cleaner cover. When installing, set the paper element and urethane foam on the air cleaner base. Check that the grommet is in position, and then install the cover with knob tightened securely.

Urethane Foam cleaning Wash and clean the urethane foam in kerosene. Saturate in a mixture of 3 parts kerosene and 1 part engine oil, and then squeeze to remove excess oil. Clean or replace the urethane foam ele- ment every 50 hours. (more often in dusty environments)

Paper element Clean by tapping gently to remove dirt and blow off dust. Never use oil. Clean or replace the paper element every 50 hours of operation, and replace element set every 200 hours or once a year.

GROMMET

ELEMENT

URETHANE FOAM

BASE

28

7UX-9-1B 13.11.4 13:37 28

0.70.8 mm (0.0280.031 in)

CLEANING FUEL STRAINER Dirt and water in the fuel are removed by the fuel strainer.

(a) Remove the strainer cup and throw away water and dirt.

(b) Clean the screen and strainer cup with gasoline.

(c) Tightly fasten the cup to main body, making sure to avoid fuel leak.

CLEANING AND ADJUSTING SPARK PLUG (a) Unplug the high-voltage cables (locat-

ed at the outlet panel and lead-acid battery).

(b) Using the supplied plug wrench and handle, turn it counterclockwise until it comes off.

(c) Clean the area around the mounting hole.

(d) Clean the electrodes if they are dirty. Adjust the clearance to 0.70.8 mm (0.0280.031 in). Replace it with a new one if the abrasion has devel- oped to the degree where a flat sur- face cannot be obtained on its projec- tion. If the electrodes turn black, also inspect the air cleaner.

(e) Attach and tighten the plug with the specified torque : 2530 Nm (2.53.0 mkgf, 1822 ftlbf).

( f ) After checking that the contact area inside the plug cap is not corroded, connect the high-voltage cables.

Spark plug

NGK BPR5ES

29

7UX-9-1B 13.11.4 13:37 29

CHECKING CARBON BRUSH If the brush become excessively worn, its contact pressure with the slip ring changes and causes a roughened surface on the slip ring, resulting in irregular gen- erator performance.

Check the brush every 500 hours or if generator performance is irregular.

If the brush is 5 mm (0.2 in) long or less, replace it with a new one.

(a) Remove the brush cover.

(b) Disconnect the wire connector and remove the brush.

(c) Carefully note the brush direction and relative position with the slip ring when installing new brush.

155 mm (0.60.2 in)

BRUSH

BRUSH HOLDER

BRUSH COVER

BRUSH HOLDER

FLANGE BOLT

SCREW

FUEL HOSE REPLACEMENT

Replace the fuel hose every 1,000 hours or every 2 years. If fuel hose leak is found, replace the fuel hose immediately.

Take extreme caution when replacing fuel hose ; gasoline is flammable.

WARNING

30

7UX-9-1B 13.11.4 13:37 30

AE00481

BATTERY Replenishing the battery fluid 1. Check the fluid level. The level should

be between the upper and lower level marks.

1 Upper level 2 Lower level

2. Add only distilled water if necessary.

762-035

q

w

762-036

762-012

Battery electrolyte is poisonous and dangerous. It contains sulfuric acid and can cause severe burns. 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 vegetable oil. Call physician immediately.

EYES: Flush with water for 15 min- utes and get prompt medical atten- tion.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield your eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

Normal tap water contains minerals which are harmful to a battery; there- fore, refill only with distilled water.

WARNING

NOTICE

31

7UX-9-1B 13.11.4 13:37 31

SPARK ARRESTER In a dry or wooded area, it is recommendable to use the engine with a spark arrester. Some areas require the use of a spark arrester. Please check your local laws and regulations before operating your engine.

The spark arrester must be cleaned regularly to keep it functioning as designed. A clogged spark arrester :

Prevents the flow of exhaust gas Reduces engine output Increases fuel consumption Makes starting difficult

How to remove the spark arrester 1. Remove the flange bolts from the

muffler cover and remove the muffler cover.

2. Remove the screw from the spark arrester and remove the spark arrester from the muffler.SPARK

ARRESTER

MUFFLER

SCREW

SPARK ARRESTER SCREEN Clean the spark arrester screen Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen.

The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged.

Install the spark arrester, and muffler protector in the reverse order of disassembly.

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.

WARNING

SPARK ARRESTER

32

7UX-9-1B 13.11.4 13:37 32

PREPARATION FOR STORAGE

The following procedures should be followed prior to storage of your generator for a period of 6 months or longer.

Drain fuel from fuel tank and strainer (cup) carefully by disconnecting the fuel line. Gasoline left in the fuel tank will eventually deteriorate making engine-starting difficult.

Drain fuel from the carburetor by loos- ening the drain screw on the carburetor float chamber , or run the engine at no-load until it stops.

Disconnect the terminal of the battery.

Change engine oil.

Check for loose bolts and screws, tighten them if necessary.

Clean generator thoroughly with oiled cloth. Spray with preservative if avail- able. NEVER USE WATER TO CLEAN GENERATOR !

Store generator in a well ventilated, low humidity area.

Screw for Drain

33

Fuel is highly flammable and poisonous. Check "SAFETY INFORMATION" (See page 3) carefully.

WARNING

Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted sur-faces or plastic parts.

NOTICE

7UX-9-1B 13.11.4 13:37 33

AE00633

BATTERY 1. Remove the battery.

2. Check the fluid level. Add only distilled water if necessary. (See page 31 "BATTERYReplenishing the battery fluid")

3. After checking the fluid level, charge the battery.

4. Store the battery in a cool, dark and dry place. Do not store the battery in an excessively warm or cold place [i.e., less than 0C (30F) or more than 30C (90F)].

5. Check battery condition with a hydrometer monthly, and charge as necessary.

Disconnect the negative lead first, then the positive lead from the battery. Connect the positive lead first, then the negative lead to the battery when

installing the battery. Never smoke or make and break connections at the battery while charging.

Sparks may ignite the battery gas. Be sure the battery terminals are tight and that the battery vent tube is prop-

erly routed and is securely attached to the battery.

34

WARNING

Do not disconnect the battery during engine operation. Avoid operating the generator with the battery removed.

NOTICE

HIGH ALTITUDE ENGINE OPERATION Please have an authorized Yamaha dealer modify this engine if it is to be run con-

tinuously above 5000 feet (1500 meters). Failure to do so, may result in poor engine performance, spark plug fouling, hard starting, and increased emissions.

Carburetor modification by an authorized Yamaha dealer will improve perfor- mance and allow that this engine meets EPA (Environmental Protection Agency) and California ARB (Air Resources Board) emission standards throughout its useful life.

An engine converted for high altitudes can not be run at 5000 feet or lower. In doing so, the engine will overheat and cause serious engine damage. Please have an authorized Yamaha dealer restore high altitude modified engines to the original factory specification before operating below 5000 feet.

7UX-9-1B 13.11.4 13:37 34

TROUBLESHOOTING

When generator engine fails to start after several attempts, or if no electricity is available at the output receptacles, check the possible causes in accordance with the following table. If your generator still fails to start or generate electricity, con- tact your nearest Yamaha dealer or authorized service center for further informa- tion or corrective procedures.

Possible causes

Problem

Lo w

b at

te ry

B lo

w n

fu se

D et

er io

ra te

d fu

el F ue

l p ip

in g

C lo

gg in

g of

A ir

cl ea

ne r

C lo

gg in

g of

C oo

lin g

ai r

in ta

ke

Lo w

o il

le ve

l

F au

lty s

pa rk

p lu

g

O ve

rlo ad

b y

co nn

ec te

d ap

pl ia

nc e

In co

rr ec

t o r

po or

c on

ne ct

io n

of w

ire s

In su

ffi ci

en t c

ap ac

ity o

f e xt

en si

on c

ab le

Starter will not run

Le ak

ag e

Starter runs, but Engine will not start.

C lo

gg in

g

D ur

in g

op er

at io

n Rotation decreased Unstable rotation

Breaker turned off

C

ar bo

n br

us he

s ar

e ex

ce ss

iv el

y w

or n

Low power

The starter motor will not run : Wait for more than 0.5 second after the engine is stopped and then turn the

starter switch to the "START" position. If a remote control unit is connected, check if both starter switch on the control

panel and the engine switch on the remote control unit are switched on.

The engine stopped and the oil pressure warning lamp flashed for three minutes. Check the following.

No fuel in the fuel tank Supply fuel Fuel cock not open Turn on fuel cock No sufficient engine oil Add or change engine oil

35

7UX-9-1B 13.11.4 13:37 35

SPECIFICATIONS

Model

Remote controller terminal (Auto choke)

Standard

EF12000DE

A lt

er n

at o

r

Type

Rated voltage

Brush, Self-exciting, 2-pole, Single phase

611 mm (24.1 in) [758 mm (29.8 in)]*1

Rated frequency 60 Hz

771 mm (30.4 in) [856 mm (33.7 in)]*1

120V / 240V

Rated output 9500 VA

Maximum output 12000 VA

Large

Power factor 1.0

Width

Voltage regulator

High

A.V.R type

E n

g in

e

Model EH65D

Type Twin cylinder, Air-cooled, 4-stroke, Overhead valve engine

Displacement 653 cm3

Fuel Automotive Unleaded Gasoline

Oil capacity 1.55 L (1.64 US qt, 1.36 Imp qt)

Starting system Electric starter

Fuel tank capacity 38 L (10.04 US gal, 8.36 Imp gal)

Rated continuous operation per a tankful of fuel

Rated Approx. 7.1 hours

D im

en si

on

826 mm (32.5 in)

Dry weight 141 kg (310.8 lb) [149 kg (328.5 lb)]*2

Specifications are subject to change without notice. *1: [ ] shows dimensions with castors. *2: [ ] shows dry weight with castors installed.

Rated current 79.2 A / 39.6 A

Valve clearance (Intake & Exhaust)

0.1 0.02 mm (0.0039 0.0008 in) Note : Adjust the valve clearance while the engine is cold.

36

7UX-9-1B 13.11.4 13:37 36

CONSUMER INFORMATION

YAMAHA MOTOR CO,LTD. MADE IN JAPAN

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

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

TIP The first three digits of these numbers are for model identification; the remain- ing digits are the unit production num- ber. Keep a record of these numbers for reference when ordering parts from a Yamaha dealer.

PRI-I.D. CODE

MODEL

SERIAL No.

PRI-I.D. NUMBER

37

7UX-9-1B 13.11.4 13:37 37

WIRING DIAGRAM

5 3 2

4

(AC output)

(AVR)

1

CONTROL BOX

Fuel cut

Ignition coil

Auto choke (Bimetal)

Electric starter

Oil pressure switch

Regulator

Magnetic switch

Charge coil

Exciting coil

- +

Battery 12V Grn

Grn/Y

Org

Gry

Blk

R

Starter switch

to earth terminal

ST Relay

Connector (Remote control)

Gry

R15

B lk

15

Grn

W Blk/W

Gry

Gry

Blk

(AC 120V)

R

Blk/W Blk

R

Grn/Y Grn/Y

Grn

Grn

Org OrgR

Org

LBlu

LBlu

Brn Y

Org

R

W

W

W

W W

W W

OFF -M +M B L.IG ST

ON START

R/W

Idle solenoid 1

Electronic control unit

2

13

3

12

4

11

5

10

6

9 8 7

B lk

Y Y

B lk

R

Blk

Grn/Y

Grn/Y Economy switch

Idle control

unit

Oil pressure warning lamp

(Red)

LGrn

Org

Blk

Blk R

Blu

Blk

B lk

R

R

W

W

W

LGrn

Grn/Y Grn/Y

Grn/Y

Brn

CONTROL BOXGENERATOR

Fuse

Y Y

No-fuse breaker

V ol

tm et

er

H ou

r m

et er

P ilo

t l am

p

VHr PL

Earth(Ground) terminal

Field Winding

A C

W in

di ng

1 A

C W

in di

ng 2

AVR

w w

Id le

co

nt ro

l un

it

AC output receptacle(120V)

REC2

AC output receptacle (120V) REC1

AC output receptacle (120/240V) REC3

AC output receptacle (120/240V) REC4

Engine Exciting coil

to Idle control unitto Starter

switch

Grn/Y

W Brn

Blk

(4P)

LGrn Blk

LGrn W

Brn

G rn

/Y

BrushBrush

Auxiliary Winding for Condenser

Connector Remote control

Wiring color cord

LGrn R/W Blk/RBlk Black Brn/W Brown/White R Red

Blk/W Black/White Grn Green W White Blu Blue Grn/W Green/White Y Yellow LBlu Light blue Org Orange Pik Pink Brn Brown Gry Gray Grn/Y Green/Yellow

: : : : :

: : : : :

: : : : :

: : :

Light green Red/White Black/Red

38

7UX-9-1B 13.11.4 13:37 38

OPTIONAL PARTS

"HOW-TO" INSTALL THE WHEEL (1) Checking of supplied accessories

(2) Tool preparation

Hoist or square bar (100 mm (3.94 in) by 100 mm (3.94 in), length : 700 mm (27.56 in))

Pliers

Spanner or socket wrench (12 mm (0.472 in)), 2 units

(3) Installation procedures

(a) Raise the generator by about 100 mm (3.94 in), with hoist or with square bar put under the bottom panel.

(b) Attach wheel mounting parts ,, stopper , using clamp ,, and wheel , to wheel shaft . Then check that wheel is rotated smoothly. If moving turns out to be too complicat- ed, assemble them together using grease. (4 locations / 2 pieces)

(c) Bend the tip of according to the shape of wheel shaft as possible.

(d) Attach the assembled shaft to the foundation plate of the engine, using , , and .

(e) Attach the other shaft to the foundation plate of the generating unit, using and . ( is not used.) The tightening torque of bolts should be 2025 Nm (2.02.5 mkgf, 1822 ftlbf).

REMOTE CONTROL UNIT

When the remote control unit is connected, the engine will not start unless both starter switch on the control panel and the engine switch on the remote control unit are switched on.

If you provide the generator with wheels, always be sure to place the generator on a level surface, locking the wheel with the stopper and /or chocking the wheels.

39

WARNING

7UX-9-1B 13.11.4 13:37 39

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 satis- faction. 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 comfort- ing 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)

40

7UX-9-1B 13.11.4 13:37 40

7UX-9-1B_hyoshi 13.11.4 10:14 2

Generator

LIT-19626-02-08 7UX-28199-1BPRINTED ON R

Manualsnet FAQs

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