Yamaha EF2400iS v3 Owner's Manual PDF

Generator

LIT-19626-01-23 7CF-28199-10PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 05 902 0.4 1 !

EF2400iS

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.

AE00002

INTRODUCTION Congratulations on your purchase of your new Yamaha. This manual will provide you with a good basic understanding of the operation and main- tenance 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.

EF2400iS OWNERS MANUAL

2005 by Yamaha Motor Corporation, U.S.A. 1st Edition, February 2005

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-19626-01-23

MODEL

790-072

7CH-24163-**

AE00022

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 dealer.

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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 manual, please consult your Yamaha dealer.

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.

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AE00041

CONTENTS

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

LOCATION OF IMPORTANT LABELS ..3

SAFETY INFORMATION ........................5

EXHAUST FUMES ARE

POISONOUS .......................................5

FUEL IS HIGHLY FLAMMABLE AND POISONOUS .......................................5

ENGINE AND MUFFLER MAY

BE HOT................................................5

ELECTRIC SHOCK PREVENTION.....6

CONNECTION NOTES .......................7

CONNECTION.....................................7

EXTENSION CORD NOTES ...............7

CONTROL FUNCTION ...........................8

DESCRIPTION ....................................8

CONTROL PANEL ...............................8

OIL WARNING SYSTEM .....................9

ENGINE SWITCH................................9

DC PROTECTOR ................................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

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

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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 warrants that new Yamaha consumer generators purchased from an authorized Yamaha consumer generator dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stat- ed limitations.

THE PERIOD OF WARRANTY Any new EF-series or EDL-series Yamaha Generator purchased for private, non-commercial use from an authorized Yamaha consumer generator dealer in the conti- nental United States will be warranted against defects in material or work- manship for a period two (2) years from date of pur- chase, 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 warranted 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 apparent defects within ten (10) days after discovery, and make the unit available at that time for inspection and repairs at such dealers place of business.

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

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 DAM- AGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU.

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

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

Cypress, California 90630

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WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibility during the warranty period?

A. The customers responsibility includes all costs of normal maintenance service, non-warranty repairs, accident damages, as well as oil and spark plugs.

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

A. These terms are general and overlap each other in areas. Specific examples include: Running the machine out of oil; lack of proper maintenance; operating the machine with a broken or damaged part which causes anoth- er part to fail; and so on. If you have any spe- cific questions on operation or maintenance, please contact your dealer for advice.

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

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

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

A. Yes, if you are a qualified mechanic and 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 war- ranty repair work.

Q. Is the warranty transferable to second owners? A. Yes. The remainder of the existing warranty

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

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha generator dealer within the continental United States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assis- tance, 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 manufactur- er to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-relat- ed 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 postcard 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.

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3

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.

4 31

2

792-063

3 4

792-064

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1 2

4

3

WARNING READ THE OWNERS MANUAL AND ALL LABELS BEFORE OPERATING.

q qAVERTISSEMENT 8

ONLY OPERATE IN WELL-VENTILATED AREAS. EXHAUST GAS CONTAINS POISONOUS CARBON MONOXIDE. CHECK FOR SPILLED FUEL OR FUEL LEAKS. STOP ENGINE BEFORE REFUELING. DO NOT OPERATE NEAR FLAMMABLE MATERIALS. ELECTROCUTION CAN OCCUR IF GENERATOR IS USED IN RAIN, SNOW, OR NEAR WATER. KEEP THIS UNIT DRY AT ALL TIMES.

8

8 8 8 8

MACHINE AUSEC EN TOUTES CIRCONSTANCES. 7CF-24162-10

8

8

8 8 8 8

LISEZ LE MODE DEMPLOI ET TOUTES LES ETIQUETTES AVANT DE FAIRE FONCTIONNER LA MACHINE. FAITES FONCTIONNER UNIQUEMENT DANS DES LIEUX BIEN AERES. LES GAZ DECHAPPEMENT CONTIENNENT DU MONOXYDE DE CARBONE. VERIFIEZ SI DU CARBURANT A ETE RENVERSE OU SIL FUIT. ARRETEZ LE MOTEUR AVANT DE FAIRE LE PLEIN DE CARBURANT. NUTILISEZ PAS A PROXIMITE DE MATERIAUX INFLAMMABLES. IL Y A RISQUE DELECTROCUTION SI LE GENERATEUR FONCTIONNE SOUS LA PLUIE, DANS LA NEIGE, OU PRES DE LEAU. GARDEZ LA

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) zzz-2179R-00

HOT EXHAUST ***-28176-**

OIL

zzzzzz

AC output zzHz

Rated zzzKVA

Phase Single

DC output zzV zzA

Fuel Gasoline

YAMAHA MOTOR CO., LTD. MADE IN JAPAN

zzzV

***-24164-**

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741-112

741-113

741-114

741-115

741-116

741-117

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.

AE00075

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 muf-

fler 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 machine, be sure it is kept upright. If it tilts, fuel may leak from the carburetor or fuel tank.

AE00843

ENGINE AND MUFFLER MAY BE HOT 9 Place the machine in a place where pedestrians 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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6

741-118

a

9 Keep the machine at least 1 m (3 ft) from buildings or other equipment, or the engine may overheat.

a 1 m (3 ft)

741-119

9 Avoid operating the engine with a dust cover.

1

741-124

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

1 Carrying handle(s) (shaded)

741-120

AE00083

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

741-121

9 Never touch the machine with wet hands or electri- cal shock will occur.

741-125

1

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

1 Lead diameter

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Ground (earth) Lead Diameter:

0.12 mm (0.005 in)/ampere EX;

10 Ampere 1.2 mm (0.05 in)

1

2

1

741-122

AE01181

CONNECTION NOTES 9 Avoid connecting the generator to commercial

power outlet.

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 sup- ply has failed or has been turned off for line repair. Backfeeding can electrocute or injure line mainte- nance personnel. Also, generator and building electrical system damage can occur when normal 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.

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AE00101

CONTROL FUNCTION

56

23

4

1 1

793-146

1 123

7 793-147

q w e r

o i u

t y

793-148

AE00103

CONTROL PANEL 1 Engine switch 2 Twin Tech (parallel running terminal) 3 DC protector 4 Oil warning light 5 AC pilot light 6 Overload indicator light 7 AC receptacle 8 DC receptacle 9 Ground (Earth) terminal

AE00102

DESCRIPTION 1 Carrying handles (shaded) 2 Fuel level gauge 3 Fuel tank cap 4 Oil filler cap 5 Recoil starter 6 Fuel cock 7 Muffler

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700-121

763-259

q

w

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.

AE00124

ENGINE SWITCH 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.

763-260

763-238a

q

w

AE00780

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 I ON 2 3 OFF

763-263

AE01179

TWIN TECH (TERMINAL FOR CONNECTING SPECIAL CABLES FOR PARALLEL RUNNING ) This is the terminal for connecting special cables for par- allel running of two EF2400iS. The parallel running requires two EF2400iS and the special cables. (The rated output in parallel running is 3.6 kVA and the rated current is 30.0 A.) The handling, operation procedure and the notes on usage are described in the PARALLEL RUNNING KIT OWNERS MANUAL included in the Parallel Running Kit. Consult a Yamaha dealer for this Parallel Running Kit.

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10

741-123

707-033c

q

707-106

707-037

707-107

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.

AE00856

FUEL Make sure there is sufficient fuel in the tank.

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

1 Fuel level gauge

w 9 Fuel is highly flammable and poisonous. Check

SAFETY INFORMATION (See page 5) careful- ly 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.

Recommended fuel: Unleaded gasoline

Fuel tank capacity: Total: 6.0 L (1.32 Imp gal, 1.59 US gal)

F Full E Empty

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11

700-128

741-126

700-103c

q

700-065

0C 25C

80F32F

A YAMALUBE 4(10W-30)

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

700-006

AE00222

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

1 Upper level

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

cC The generator has been shipped without engine oil. Fill with oil or it will not start.

AE00241

GROUND (Earth)

Make sure to ground (earth) the generator. Check SAFETY INFORMATION on page 6.

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

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

Engine oil quantity: 0.6 L (0.53 lmp qt, 0.63 US qt)

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12

700-006a

a

761-085

705-075

1

AE00955

OPERATION

NOTE: The generator has been shipped without engine oil. Fill with oil or it will not start.

1 Upper level

AE01171

STARTING THE ENGINE

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

electric devices.

1. Turn the fuel cock lever to the ON position.

1 ON

2. Pull the choke knob fully out.

2 Choke knob

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

3. Turn the engine switch to the 7 (ON) position. 3 7 ON

701-051

2

e

763-261

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

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

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

NOTE: When starting the engine in areas where the ambient temperature is below 0C (32F), the engine automati- cally operates at the rated r/min (3,200 r/min) for three minutes to warm up the engine

704-019

701-051a

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AE01180

APPLICATION RANGE

AC DC

Power factor 1 0.80.95 0.40.75

(Efficiency 0.85)

EF2400iS 2,000W 1,600W 680W

Rated voltage 12V

Rated current 8A

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

used by itself. 9 The overload indicator light 1 comes on when

total wattage exceeds the application range. (See page 16 for more details.)

cC 9 Be sure the total load is within generator rated

output otherwise generator damage will occur. 9 Do not use AC and DC power at the same time

or the generator may be damaged.

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 provide power to such equipment.

q

760-029

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15

761-086

761-085a

q

760-030

AE01172

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 on any electric devices.

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16

q

760-029

AE00788

Overload indicator light The overload indicator light 1 comes on when an over- load 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 generator 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 running.

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 com- pressor or a submergible pump. However, this is not a malfunction.

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17

761-086a

762-046

12

12v 762-047

763-238a

q

w

AE00904

Battery Charging

cC Do not use AC and DC power at the same time or the generator may be damaged.

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 battery leads are properly connect-

ed. 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 ON 2 OFF

NOTE: 9 At full charge, electrolyte specific gravity is

between 1.26 and 1.28. 9 Check specific gravity hourly.

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w Never smoke or make and break connections at the battery while charging. Sparks may ignite the bat- tery gas. Battery electrolyte is poisonous and dangerous, causing severe burns, etc. contains sulfuric (sul- phuric) acid. Avoid contact with skin, eyes or cloth- ing. 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.

762-012

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761-085

763-262

q

705-075a

2

AE01173

STOPPING THE ENGINE

NOTE: 9 Turn off any electric devices.

1. Disconnect any electric devices.

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

1 5 STOP

3. Turn the fuel cock lever to OFF.

2 OFF

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20

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

0 Spark 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.

4.* ** Check and adjust 0Idle speed

engine idle speed.

Check for leakage. Retighten or

0 *replace gasket

** if necessary.

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

Check oil level 0 6. Engine Oil

Replace 0 0

** Clean. 7. Air Filter Replace if 0

necessary.

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.

7CF-9-10-b 3/9/05 10:35 AM 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.

Clean fuel tank 8. Fuel Filter filter. Replace if 0

necessary.

Check fuel hose

9. Fuel Line for crack or da-

0 mage. *Replace if necessary.

10. ** Check choke 0Choke knob

operation.

11. Cooling System Check for fan

0 damage.

Check recoil 012. Starting System

starter operation.

13.* ** More frequently

0Decarbonization if necessary.

14. Generation Check the pilot

0 light comes on.

Check all fittings

15.* 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

7CF-9-10-b 3/9/05 10:35 AM Page 21

22

788-014

1 1

2

760-031

a

760-001a

AE01051

SPARK PLUG INSPECTION You should periodically remove and inspect the spark plug. 1. Loosen the bolt 1 and remove the side cover 2. 2. Remove the spark plug cap and the spark plug. 3. Check for discoloration and remove the carbon.

4. Check the spark plug type and gap.

a Gap

5. Install the spark plug.

6. Install the spark plug cap. 7. Install the side cover and tighten the bolt.

Standard electrode color: Tan Color

Standard Spark Plug: BPR4ES (NGK)

Spark Plug Gap: 0.70.8 mm (0.0280.031 in)

Spark Plug Torque: 17.5 Nm (1.75 kgfm, 13 lbfft)

AE00431

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

7CF-9-10-b 3/9/05 10:35 AM Page 22

23

700-133

3

3

6 4

700-006a

q

AE01174

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

the engine for several minutes. Then stop the engine.

2. Remove the rubber cap 1 on the bottom.

3. Place an oil pan under the engine . Remove the drain bolt 2.

4. Open the oil filler cover 3 as shown and remove the oil filler cap 4 so that the oil can be complete- ly drained.

5. Check the drain bolt , gasket 5, oil filler cap and O- ring 6. If damaged, replace.

6. Reinstall the oil drain bolt.

7. Add engine oil to the upper level. 1Upper level

700-130

1

700-132

2

5

Drain Bolt Torque: 17 Nm (1.7 kgfm, 12 lbfft)

7CF-9-10-b 3/9/05 10:35 AM Page 23

24

741-123

788-016

1

711-077

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

2. Remove the muffler screen.

2 Muffler screen 3 Screw

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

cC Be sure no foreign material enters the crankcase.

8. Install the oil filler cap. 9. Install the rubber cap on the bottom.

cC Be sure to install securely to prevent from falling off during operation.

10. Close the oil filler cover.

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: 0.6 L (0.53 Imp qt, 0.63 US qt)

7CF-9-10-b 3/9/05 10:35 AM Page 24

25

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

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.

9. Install the cover.

711-080

q w

711-081

788-016a

711-079

q

711-075

4. Remove the spark arrester.

1 Spark arrester

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.

711-078

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

7CF-9-10-b 3/9/05 10:35 AM Page 25

26

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

5. Insert the element into the air filter.

NOTE: Be sure the element sealing surface matches the air fil- ter so there is no air leak.

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.

6. Install the air filter cover. 7. Install the cover and tighten the bolt.

710-037a

2. Remove the air filter cover and element.

3. Wash the foam element in solvent and dry.

4. Oil the foam element and squeeze out excess oil. The foam element should be wet but not dripping.

Recommended oil: Foam-air-filter oil

or SAE #20 motor oil

E01175

AIR FILTER 1. Loosen the bolt 1 and remove the cover 2.

788-017

1

2

1

7CF-9-10-b 3/9/05 10:35 AM Page 26

27

707-108

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.

7CF-9-10-b 3/9/05 10:35 AM Page 27

28

707-106

705-075b

700-006

763-261a

760-009

AE01176

TROUBLESHOOTING

Engine wont start 1. Fuel systems

No fuel supplied to combustion chamber. 2 No fuel in tank .... Supply fuel.

2. Engine oil system Insufficient

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

3. Electrical systems 2 Engine switch to ON.

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

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

4. Compression Insufficient

2 Worn out piston and cylinder .... Consult dealer. 2 Loose cylinder head nuts .... Tighten nuts properly. 2 Damaged gasket .... Replace gasket.

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 Fuel in tank .... Fuel cock lever to ON. 2 Clogged fuel line .... Clean fuel line. 2 Clogged carburetor .... Clean carburetor.

7CF-9-10-b 3/9/05 10:35 AM 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.

7CF-9-10-b 3/9/05 10:35 AM Page 29

30

707-109

1

712-030

AE00601

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

AE01177

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 5) careful- ly.

9 Wipe up any spilled fuel immediately.

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

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

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.

7CF-9-10-b 3/9/05 10:35 AM 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 practice docu- ment J1930, Diagnostic Acronyms, Terms, and Definitions For Electrical/Electronic System.

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

7CF-9-10-b 3/9/05 10:35 AM Page 31

32

Unit EF2400iS Type Forced air cooled 4-stroke gasoline OHV Cylinder Arrangement Inclined, 1 cylinder Displacement cm3 171 Bore Stroke mm (in) 66.0 50.0 (2.60 1.97) Rated Output kW(HP)/r/min 2.5 (3.4)/3,200 Operation Hours at rated operation Hr 8.6 Fuel Unleaded gasoline Fuel Tank Capacity L (Imp gal, US gal) 6.0 (1.32, 1.59) Engine Oil Quantity L (Imp qt, US qt) 0.6 (0.53, 0.63) Ignition System TCI

Spark Plug: Type BPR4ES (NGK) Spark Plug: Gap mm (in) 0.70.8 (0.0280.031)

Noise Level* dB (A) 59

Unit EF2400iS Overall Length mm (in) 527 (20.7) Overall Width mm (in) 419 (16.5) Overall Height mm (in) 461 (18.1) Dry Weight kg (lb) 32 (72)

AE00701

SPECIFICATIONS AE00702

DIMENSIONS

AE00704

ENGINE

Unit EF2400iS

AC Output Rated Voltage V 120 Rated frequency Hz 60 Rated current A 16.7 Rated Output kVA 2.0 Safty Device: Type Electronic

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

AE00707

GENERATOR

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

7CF-9-10-b 3/9/05 10:35 AM Page 32

33

YW

W W

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AE00751

WIRING DIAGRAM

1 Main coil 2 DC coil 3 Sub coil 4 DC rectifier 5 Control unit 6 AC pilot light 7 Parallel terminal 8 AC receptacle 9 Ground (Earth) terminal 0 Overload indicator light q DC receptacle w DC protector (breaker) e Engine switch r Oil warning light t Speed limiter assembly y Oil level gauge u T.C.I. magneto i T.C.I. unit o Spark plug

p Stepping motor Color code B Black Br Brown G Green L Blue O Orange R Red W White Y Yellow B/W Black/White G/Y Green/Yellow

7CF-9-10-b 3/9/05 10:35 AM Page 33

7CF-9-10 hyoshi 2/15/05 3:01 PM Page 2

Generator

LIT-19626-01-23 7CF-28199-10PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 05 902 0.4 1 !

EF2400iS

OWNERS MANUAL

7CF-9-10 hyoshi 2/15/05 3:01 PM Page 1

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