Contents

Yamaha EF2400iSHC Owner's Manual PDF

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Summary of Content for Yamaha EF2400iSHC Owner's Manual PDF

Generator

LIT-19626-01-64 7CF-28199-15PRINTED ON RECYCLED PAPER

PRINTED IN JAPAN 2009.10-1.01 !

(E)

EF2400iSHC

OWNERS MANUAL

Read this manual carefully before operating this machine.

7CF-9-15 hyoshi 09.8.27 10:54 Page 1

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

7CF-9-15 hyoshi 09.8.27 10:54 Page 2

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.

EF2400iSHC OWNERS MANUAL

2009 by Yamaha Motor Corporation, U.S.A. 1st Edition, September 2009

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-19626-01-64

MODEL

790-072

7CF-24163-**

AE00022

AE00011

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 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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AE00032

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

TIP 9 Yamaha continually seeks advance-

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

* Product and specifications are subject to change without notice.

WARNING

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

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

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

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

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

NOTICE

WARNING

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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 LIGHT (Red) ...............9

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

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

PRE-OPERATION CHECK ...................11

FUEL..................................................11

ENGINE OIL ......................................12

GROUND (earth) ...............................12

OPERATION .........................................13

STARTING THE ENGINE ..................13

APPLICATION RANGE......................15

CONNECTION...................................16

STOPPING THE ENGINE..................21

PERIODIC MAINTENANCE .................22

MAINTENANCE CHART ...................22

SPARK PLUG INSPECTION .............24

CARBURETOR ADJUSTMENT.........25

ENGINE OIL REPLACEMENT ..........25

MUFFLER SCREEN AND SPARK ARRESTER .......................................26

AIR FILTER........................................28

FUEL TANK FILTER...........................29

TROUBLESHOOTING ..........................30

STORAGE .............................................32

DRAIN THE FUEL .............................32

ENGINE .............................................34

EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS............35

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

DIMENSIONS ....................................36

ENGINE .............................................36

GENERATOR.....................................36

WIRING DIAGRAM ...............................37

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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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2

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 generator.

TIP Maintain or replace safety and instruction labels, as necessary.

2 3 41

6

7

5

1

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.

2

Read the owner's manual and all labels befor operating. 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. When operating the generator: Never place a partition or other barrier around the generator. Do not cover the generator with a box. Do not place any objects on the generator.

WARNINGq qAVERTISSEMENT

7CF-24162-20

Lisez le mode d'emploi et toutes les etiquettes avant de faire fonctionner la machine. Faites fonctionner uniquement dans des lieux bien aeres. Les gaz d'echappement contiennent du monoxyde de carbone. Verifiez si du carburant a ete renverse ou s'il fuit. Arretez le moteur avant de faire le plein de carburant. N'utilisez pas a proximite de materiaux inflammables. Il y a risque d'electrocution si le generateur fonctionne sous la pluie, dans la neige, ou pres de l'eau, gardez la machine ausec en toutes circonstances. Quand la gnratrice est en marche: Ne jamais entourer la gnratrice de cloisons ou d'crans. Ne jamais recouvrir la gnratrice d'une bote. Ne jamais disposer d'objets sur la gnratrice.

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4

7

6

4

HOT EXHAUST 7WL-28176-10

3

Electrocution or property damage

can occur : Do not connect this

generator to any building's electrical

system unless an isolation switch

has been installed by a licensed elec-

trician. Refer to the owner's manual.

7XF-2415A-10

WARNINGq

5

NOTICE Use the specified spark plug only.

Specified plug:BPR4ES(NGK)

OIL

AC output 60Hz

Rated 2.0KVA

Phase Single

DC output 12V 8A

Fuel Gasoline

YAMAHA MOTOR POWERED PRODUCTS CO.,LTD. MADE IN JAPAN

120V

7CF-24164-E0

EF2400iSHC

Important Emissions Information The air index of this engine is 3 (California only)

MOST CLEAN LEAST CLEAN 0 2 4 6 8 10

YAMAHA MOTOR POWERED PRODUCTS CO.,LTD. This engine meets **** California exhaust and evaporative 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) EF: ********* DISPLACEMENT: *** cc EVAP F: ******** EMISSION CONTROL SYSTEM: EM This engine is certified to operate on unleaded gasoline. ENGINE OIL: SAE10W-30 TYPE: SE No other adjustments needed.

Note: The lower the air index, the less the pollution. This engine is certified to be emissions compliant for the following use:

Check owner's manual for further details.

MODERATE (*** HOURS)

INTERMEDIATE (*** HOURS)

EXTENDED (*** HOURS)X

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5

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.

AE00843

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

or children are not likely to touch the generator.

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

9 When operating or transporting the generator, be sure it is kept upright. If it tilts, fuel may leak from the carburetor or fuel tank.

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6

741-118

a

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

a 1 m (3 ft)

7CF-001

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 completely cooled down.

1 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 generator with wet hands or elec- trical shock will occur.

741-119

7CF-002

9 Do not place any obstacles on the generator.

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7

741-122

1

2

1

2

AE01181

CONNECTION NOTES 9 Avoid connecting the generator to commercial

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

other generator.

1 Correct 2 Incorrect

AE00091

CONNECTION

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.

WARNING

AE00086

EXTENSION CORD NOTES Extension cords should be protected by a tough flexible rubber sheath (IEC 245) or the equivalent to withstand mechanical stresses.

1

9 Connect the ground lead of the generator to the ground (earth) terminal and connect the end to the ground electrode buried in the ground.

1 Ground (earth) terminal

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AE00101

CONTROL FUNCTION

56

23

4

1 1

1 123

7 793-147

i u y

q w e rt

AE00103

CONTROL PANEL 1 Engine switch 2 DC protector 3 Oil warning light 4 AC pilot light 5 Overload indicator light 6 AC receptacle 7 DC receptacle 8 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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9

700-121

763-259

q

w

AE00111

OIL WARNING LIGHT (Red) When the oil level falls below the lower level, the oil warning light (Red) comes on and then the engine stops automatically. Unless you refill with oil, the engine will not start again.

TIP If the engine stalls or does not start, turn the engine switch to ON 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.

DC PROTECTOR The DC protector turns to OFF 2 automatically when electric device being connected to the generator is operating and current above the rated flows. To use this equipment again, turn on the DC protector by pressing its button to ON 1.

1 ON Direct current is output. (This is the default position.)

2 OFF Direct current is not output.

Reduce the load of the connected electric device below the specified rated output of the generator if the DC protector turns off. If the DC protector turns off again, stop using the device immediately and consult a Yamaha dealer.

NOTICE

763-260

763-238a

q

w

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10

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741-123

707-033a

1

707-106

2

707-107

AE00845

PRE-OPERATION CHECK Pre-operation checks should be made each time the generator is used.

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 2 LEVEL mark (Red)

9 Fuel is highly flammable and poisonous. Check SAFETY INFORMATION (See page 5) careful- ly before refueling.

9 Do not fill above the LEVEL mark 2 in the fuel filter or it may overflow when the fuel warms up and expands.

9 After refueling, make sure the tank cap is tight- ened securely.

WARNING

WARNING

Recommended fuel: Unleaded gasoline

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

3 F Full 4 E Empty

34

7DF-020

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12

700-128

1

700-103c

q

700-006

AE00222

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

9 Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate paint- ed surfaces or plastic parts.

9 Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal engine parts.

NOTICE

1 Upper level

The generator has been shipped without engine oil. Do not start the engine till fill with the sufficient engine oil.

NOTICE

AE00241

GROUND (earth)

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

1 Ground (earth) terminal

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

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

0C

YAMALUBE 4 (10W-40)

SAE 10W SAE #20 SAE #30

32F

25C

80F

7CF-9-15-a 09.9.8 14:53 Page 12

13

700-006a

q

705-075

1

AE00955

OPERATION

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 venti- lated area.

9 Before starting the engine, do not connect any electric devices.

The generator has been shipped without engine oil. Do not start the engine till fill with the sufficient engine oil.

1 Upper level

NOTICE

WARNING

AE01171

STARTING THE ENGINE

1. Turn the fuel cock lever to ON.

1 ON

2. Pull the choke lever fully out.

2 Choke lever

TIP The choke is not required to start a warm engine. Push the choke lever in to the original position.

3. Turn the engine switch to ON.

3 7 ON

701-051

2

e

763-261

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14

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 lever is returned to the original position.

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

TIP 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 3 min- utes to warm up the engine

701-051a

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1

AE01180

APPLICATION RANGE When using the generator, make sure the total load is within rated output of a generator. Otherwise, generator damage may occur.

9 Do not overload. The total load of all electrical appliances must not exceed the supply range of the generator. Overloading will damage the generator.

9 When supplying precision equipment, electronic controllers, PCs, electronic computers, microcomputer-based equipment or battery chargers, keep the generator a sufficient distance away to prevent electrical interference from the engine. Also ensure that electrical noise from the engine does not interfere with any other electrical devices located near the generator.

9 If the generator is to supply medical equipment, advice should first be obtained from the manufacturer, a medical professional or hospital.

9 Some electrical appliances or general-purpose electric motors have high start- ing currents, and cannot therefore be used, even if they lie within the supply ranges given in the above table. Consult the equipment manufacturer for fur- ther advice.

NOTICE

TIP 9 means below. 9 Application wattage indicates when each device is

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

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

9 The overload indicator light 1 comes on when total wattage exceeds the application range. (See page 17 for more details.)

DC AC

Power factor 1 0.80.95 0.40.75

(Efficiency 0.85)

EF2400iSHC 2,000W 1,600W 680W

Rated voltage 12V

Rated current 8A

Generator rated output 2,000VA

Frequency Power factor

1.0 1,900W AC

0.8 1,500W

96W DC

(12V/8A)

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16

q

AE01172

CONNECTION

Alternating Current (AC)

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

9 Be sure all electric devices including the lines and plug connections are in good condition before connection to the generator.

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

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

1. Start the engine.

NOTICE

WARNING

2. Plug in to the AC receptacle.

3. Make sure the AC pilot light (Green) is on.

1 AC pilot light (Green)

4. Turn on any electric devices.

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17

1

AE00788

Overload indicator light (Red)

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

TIP 9 The generator AC output automatically resets

when the engine is stopped and then restarted. 9 The overload indicator light (Red) 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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762-046

12

12v 762-047

763-238a

q

w

Battery Charging TIP 9 The generator DC rated voltage is 12V. 9 Start the engine first, and then connect the gener-

ator to the battery for charging. 9 Before starting to charge the battery, make sure

that the DC protector is turned on.

1 Red wire 2 Black wire

1. Start the engine.

2. Press in the DC protector.

3. Connect the red battery charger lead 1 to the pos- itive (+) battery terminal.

4. Connect the black battery charger lead 2 to the negative (-) battery terminal.

9 Be sure to connect the red battery charger lead to the positive (+) battery terminal, and connect the black lead to the negative (-) battery termi- nal. Do not reverse these positions.

9 Connect the battery charger leads to the bat- tery terminals securely so that they are not dis- connected due to engine vibration or other dis- turbances.

9 Charge the battery in the correct procedure by following instructions in the owners manual for the battery.

9 The DC protector turns off 2 automatically if current above the rated flows during battery charging. To restart charging the battery, turn the DC pro- tector on by pressing its button to ON 1. If the DC protector turns off again, stop charging the battery immediately and consult a Yamaha dealer.

1 ON 2 OFF

NOTICE

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TIP 9 Follow instructions in the owners manual for the

battery to determine the end of battery charging. 9 Measure the specific gravity of electrolyte to deter-

mine if the battery is fully charged. At full charge, the electrolyte specific gravity is between 1.26 and 1.28.

9 It is advisable to check the specific gravity of the electrolyte at least once every hour to prevent over- charging the battery.

Operating range of DC power supply (exclusively for charging 12-V battery) This power source is designed to charge batteries up to 40AH that are half-discharged. Do not charge batteries of a higher capacity than 40AH. The time required for recharging a battery varies depending on the discharge level of the battery. When the specific gravity of the battery reaches 1.26 to 1.28, charging is complete. When charging, check the battery's specific gravity once an hour. The average time for charging a half-discharged 40AH battery is approximately 5 hours. Be sure to check the battery fluid level before charging.

9 Do not connect any load to the battery or use the engine starter motor while charging.This causes high current to flow through the gener- ator which will burn out the coil.

9 Do not connect a VRLA (Valve Regulated Lead Acid) battery. To charge a VRLA battery, a spe- cial (constant-voltage) battery charger is required.

NOTICE

7CF-9-15-a 09.9.8 14:53 Page 19

20

762-012

9 Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID. 9 EXTERNAL: Flush with plenty of water. 9 INTERNAL: Drink large quantities of water or

milk and immediately call a physician. 9 EYES: Flush with water for 15 minutes and

seek prompt medical attention. 9 Batteries produce explosive hydrogen gas.

Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space.

9 KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN.

WARNING

7CF-9-15-a 09.9.8 14:53 Page 20

21

763-262

q

705-075a

2

AE01173

STOPPING THE ENGINE

TIP Turn off any electric devices.

1. Disconnect any electric devices.

2. Turn the engine switch to STOP.

1 5 STOP

3. Turn the fuel cock lever to OFF.

2 OFF

7CF-9-15-b 09.9.8 14:50 Page 21

22

AE00401

PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your generator in the safest and most efficient condition possible. The most impor- tant points of generator inspection, adjustment, and lubrication are explained on the fol- lowing pages.

If you are not familiar with maintenance work, have a Yamaha dealer do it for you.

AE00403

MAINTENANCE CHART

Stop the engine before starting maintenance work.

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

NOTICE

WARNING

WARNING

Item Routine Pre-

operation check

Every

6 months or 100 Hr

12 months or 300 Hr

Spark plug Check condition.

1 Clean and replace if necessary.

Fuel Check fuel level and leakage. 1

Fuel hose Check fuel hose for cracks or damage. 1

Replace if necessary.

Engine oil Check oil level in engine. 1

Replace 1(*1)

Air filter element Check condition.

1(*2) Clean

Muffler screen Check condition.

1 Clean and replace if necessary.

Spark arrester Check condition.

1 Clean and replace if necessary.

Fuel filter Clean and replace if necessary. 1

7CF-9-15-b 09.9.8 14:50 Page 22

23

*1 Initial replacement of the engine oil is after one month or 20 hours of operation. *2The air filter element needs to be cleaned more frequently when using in unusually wet or dusty areas. Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

Item Routine Pre-

operation check

Every

6 months or 100 Hr

12 months or 300 Hr

Crankcase breather Check breather hose for cracks or

hose damage. 1

Replace if necessary.

Cylinder head Decarbonize cylinder head.

More frequently if necessary.

Valve clearance Check and adjust when engine is cold.

Fittings / fasteners Check all fittings and fasteners.

Correct if necessary.

The point where abnormality was recognized by use 1

7CF-9-15-b 09.9.8 14:50 Page 23

24

788-014

1 1

2

760-031

a

760-001a

AE01051

SPARK PLUG INSPECTION The spark plug is important engine components, which should be checked periodically.

1. Remove the screws 1 and side cover 2.

2. Remove the spark plug cap and the spark plug.

3. Check for discoloration and remove the carbon. The porcelain insulator around the center elec- trode of spark plug should be a medium-to-light tan color.

4. Check the spark plug type and gap a.

TIP The spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specifi- cation.

5. Install the spark plug.

TIP If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4- 1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible.

6. Install the spark plug cap.

7. Install the side cover and tighten the screws.

Standard Spark Plug: BPR4ES (NGK)

Spark Plug Gap a: 0.70.8 mm (0.0280.031 in)

Spark Plug Torque: 20 Nm (2.0 mkgf, 14 ftlbf)

7CF-9-15-b 09.9.8 14:50 Page 24

25

4

4

6 5

700-130

1

700-132

2

3

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.

AE01174

ENGINE OIL REPLACEMENT

Avoid draining the engine oil immediately after stopping the engine. The oil is hot and should be handled with care to avoid burns.

1. Place the generator 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.

WARNING

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

4. Open the oil filler cover 4 as shown and remove the oil filler cap 5 so that the oil can be complete- ly drained.

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

7CF-9-15-b 09.9.8 14:50 Page 25

26

741-123

788-016

2

11

AE01028

MUFFLER SCREEN AND SPARK ARRESTER

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 screws 1 and the cover 2.

WARNING

Be sure no foreign material enters the crankcase.

8. Install the oil filler cap.

9. Install the rubber cap on the bottom.

TIP Be sure to install securely to prevent from falling off dur- ing operation.

10. Close the oil filler cover.

NOTICE

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

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

0C

YAMALUBE 4 (10W-40)

SAE 10W SAE #20 SAE #30

32F

25C

80F

Drain Bolt Torque: 17 Nm (1.7 mkgf, 12 ftlbf)

700-006a

q

6. Install the oil drain bolt.

7. Add engine oil to the upper level.

1Upper level

7CF-9-15-b 09.9.8 14:50 Page 26

27

711-080

q w

711-081

711-079

q

711-075

4. Remove the spark arrester 1.

711-078

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

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

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

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

7. Install the spark arrester. TIP Align the spark arrester projection 1 with the hole 2 in the muffler pipe.

8. Install the muffler screen and tighten the bolt.

NOTICE

711-077

1 2

2. Losen the bolt 1 then remove the muffler screen 2.

7CF-9-15-b 09.9.8 14:50 Page 27

2. Remove the air filter cover 3 and foam element 4.

3. Wash the foam element in solvent and dry.

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

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

WARNING

28

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

5. Insert the foam element into the air filter case.

TIP Be sure the foam element sealing surface matches the air filter so there is no air leak.

NOTICE

710-037a

3 4

Recommended oil: Foam-air-filter oil or SAE #20 motor oil

E01175

AIR FILTER 1. Remove the screws 1 and remove the cover 2.

788-017

1

2

1

788-016a

1

22

9. Install the cover 1 and tighten the screws 2.

7CF-9-15-b 09.9.8 14:50 Page 28

29

707-108

q

AE00471

FUEL TANK FILTER

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

1. Remove the fuel tank cap and filter 1.

2. Clean the filter with gasoline. If damaged, replace it.

3. Wipe the filter and install it.

4. Install the fuel tank cap.

Be sure the fuel tank cap is tightened securely.

WARNING

WARNING

The engine should never run without the foam ele- ment; excessive piston and cylinder wear may result.

6. Install the air filter cover.

7. Install the cover and tighten the screws.

NOTICE

7CF-9-15-b 09.9.8 14:50 Page 29

30

707-106

705-075b

700-006

763-261a

791-001d

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.

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.

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

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

7CF-9-15-b 09.9.8 14:50 Page 30

A ENGINE DOES NOT START

B

31

P OK

O Clogged

C Does not flicker D Flickers.

AE00515

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)

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.

WARNING

Does not sparkI 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.

L Incorrect M OK Replace or Adjust Gap.

Clean the spark plug.

F OK G Level low

Consult a Yamaha dealer.

Add engine oil.

OK

E Check engine oil level.

K Check the spark plug. 9 Type: BPR4ES 9 Gap: 0.70.8 mm (0.0280.031 in)

7CF-9-15-b 09.9.8 14:50 Page 31

32

AE00601

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

4. Turn the fuel cock lever to ON 1.

5. Start the engine and leave it run until it stops. The engine stops in approx. 20 mins. time by run- ning out of fuel.

TIP 9 Do not connect with any electrical devices.

(unloaded operation) 9 Duration of the running engine depends on the

amount of the fuel left in the tank.

763-262

q

707-109a

q

763-261

705-075

1

AE01177

DRAIN THE FUEL 1. Turn the engine switch to STOP 1.

2. Remove the fuel tank cap. Extract the fuel from the fuel tank into an approved gasoline container using a commercially available handsiphon. Then, install the fuel tank cap.

Fuel is highly flammable and poisonous. Check SAFETY INFORMATION (See page 5) carefully.

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

3. Turn the engine switch to ON 1.

NOTICE

WARNING

7CF-9-15-b 09.9.8 14:50 Page 32

33

6. Remove the screws 1, and then remove the cover 2.

7. Drain the fuel remaining in the carburetor into an approved container by loosening the drain screw 1 on the carburetor float chamber.

8. Turn the engine switch to OFF.

9. Turn the fuel cock lever to OFF.

10. Tighten the drain screw 1.

11. Install the cover and tighten the screws.

788-014

1 1

2

707-109b

1

12. Tighten further if any screws, bolts and nuts are loose.

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

7CF-9-15-b 09.9.8 14:50 Page 33

34

AE00621

ENGINE Perform the following steps to protect the cylinder, pis- ton ring, etc. from corrosion.

1. Remove the spark plug, pour about one table- spoon of SAE 10W-30 or 20W-40 motor oil into the spark plug hole and install 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-9-15-b 09.9.8 14:50 Page 34

35

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-9-15-b 09.9.8 14:50 Page 35

Unit EF2400iSHC 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) Operation Hours Hr 5.08.6 (rated load1/4 load) Fuel Unleaded gasoline Fuel Tank Capacity L (US gal, Imp gal) 6.0 (1.59, 1.32) Engine Oil Quantity L (US qt, Imp qt) 0.6 (0.63, 0.53) Ignition System TCI

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

Noise Level* dB (A) 60

36

Unit EF2400iSHC 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) 34 (75)

AE00701

SPECIFICATIONS AE00702

DIMENSIONS

AE00704

ENGINE

Unit EF2400iSHC

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-9-15-b 09.9.8 14:50 Page 36

37

YW

W W

W W

W W Y

Y Y Y Y

G

O

Y

L

R

Y

B/W

O O

B/W

R R

L

L L

L

GG

OO

O O O

OO

B/W O

Y

Y

Y

Y

Y

LL

O O O

O L

L

G/Y

G/Y

G/Y

G/Y

G/Y

Y

B/W

Y

B/WB/W

R

R

Br

Br

B

B W

B

O

B/W

R

R

Br

Br

R

Br

B

W

B/W

G/Y G/Y

B/W

L

L

q

e

w

r

!9

!8 !5

!6 !4 !2

!1 !7

!3

!0

o

i

u

yt

AE00751

WIRING DIAGRAM

1 Main coil 2 DC coil 3 Sub coil 4 DC rectifier 5 Control unit 6 AC pilot light 7 AC receptacle 8 Ground (earth) terminal 9 Overload indicator light 0 DC receptacle q DC protector (breaker) w Engine switch e Oil warning light r Speed limiter assembly t Oil level gauge y T.C.I. magneto u T.C.I. unit i Spark plug o 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-9-15-b 09.9.8 14:50 Page 37

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

7CF-9-15 hyoshi 09.8.27 10:54 Page 2

Generator

LIT-19626-01-64 7CF-28199-15PRINTED ON RECYCLED PAPER

PRINTED IN JAPAN 2009.10-1.01 !

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