Yamaha EF1600 User Manual

OWNER’S MANUAL

Generator

EF1600 EF2600

YG2600

LIT-19626-01-14 7NJ-28199-12

AE00002

INTRODUCTION

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

PRI-I.D. NUMBER

MODEL

PRI-I.D. CODE

SERIAL No.

790-062

790-025a

AE00022

AE00012

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. numbers in a separate place in case your machine is stolen.

AE00011

MACHINE IDENTIFICATION

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

NOTE:

The first three digits of these numbers are for model identification; the remaining digits are the unit production number. Keep a record of these numbers for reference when ordering parts from a Yamaha dealer.

EF1600/EF2600/YG2600

OWNER’S MANUAL

1st Edition, August 2003

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-19626-01-14

851-005

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

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

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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

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.

AE00041

LIMITED WARRANTY (EF- AND

EDL-SERIES) ........................................1

LIMITED WARRANTY (EC- AND

YG-SERIES) ..........................................2

LOCATION OF IMPORTANT

LABELS.................................................4

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 BOX..................................9

OIL WARNING SYSTEM..................10

ENGINE SWITCH.............................10

AC SWITCH (N.F.B.) ........................10

G.F.C.I. RECEPTACLE ....................11

PRE-OPERATION CHECK .................12

FUEL.................................................12

ENGINE OIL .....................................13

GROUND (Earth)..............................13

OPERATION........................................14

STARTING THE ENGINE.................14

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

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

STOPPING THE ENGINE ................17

PERIODIC MAINTENANCE ................18

MAINTENANCE CHART ..................18

SPARK PLUG INSPECTION............20

CARBURETOR ADJUSTMENT .......20

ENGINE OIL REPLACEMENT .........21

AIR FILTER ......................................22

FUEL COCK .....................................23

FUEL TANK FILTER.........................23

MUFFLER SCREEN AND SPARK

ARRESTER ......................................24

G.F.C.I. RECEPTACLE TEST ..........25

TROUBLESHOOTING......................26

STORAGE ...........................................28

DRAIN THE FUEL ............................28

ENGINE ............................................28

EXHAUST EMISSION CONTROL

SYSTEM AND COMPONENTS...........29

SPECIFICATIONS ...............................30

DIMENSIONS ...................................30

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

GENERATOR ...................................30

WIRING DIAGRAM..............................31

EF1600/EF2600................................31

YG2600.............................................32

ENGINE HANGER

INSTALLATION ..................................33

AE01119

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 stated limitations.

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

DURING THE PERIOD OF WARRANTY any authorized Yamaha consumer generator dealer will, free of charge, repair or replace, at Yamaha’s 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 product’s 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 routine maintenance.

THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to:

1. Operate and maintain the generator as speci-

fied in the appropriate Owner’s Manual;

2. Give notice to an authorized Yamaha consumer 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 dealer’s place of business.

WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent purchaser(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 warranty be extended beyond the original period.

YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY.

SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR 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

– 1 –

YAMAHA MOTOR CORPORATION U.S.A.

EC- AND YG-SERIES INDUSTRIAL GENERATOR LIMITED WARRANTY

Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha EC- and YG-series generators purchased from an authorized Yamaha industrial 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 stated limitations.

THE PERIOD OF WARRANTY for Yamaha ECseries and YG-series generators shall be one (1) year from the date of purchase.

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

DURING THE PERIOD OF WARRANTY any authorized Yamaha industrial generator dealer will, free of charge, repair or replace, at Yamaha’s 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 product’s 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 routine maintenance.

THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to:

1. Operate and maintain the diesel generator as

specified in the appropriate Owner’s Manual;

2. Give notice to an authorized Yamaha industri-

al 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 dealer’s place

of business.

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

– 2 –

WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibility during the

warranty period? A. The customer’s responsibility includes all

costs of normal maintenance service, non-

warranty repairs, accident damages, as well

as oil and spark plugs.

Q. What are some examples of “abnormal” strain,

neglect, or abuse? A. These terms are general and overlap each

other in areas. Specific examples include:

Running the machine out of oil; lack of proper

maintenance; operating the machine with a

broken or damaged part which causes anoth-

er part to fail; and so on. If you have any

specific questions on operation or mainte-

nance, please contact your dealer for advice.

Q. Does the warranty cover incidental costs such

as transportation due to a failure? A. No. The warranty is limited to repair of the

machine itself.

Q. May I perform any or all of the recommended

maintenance shown in the Owner’s Manual

instead of having the dealer do them? A. Yes, if you are a qualified mechanic and follow

the procedures specified in the Owner’s 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 Owner’s 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 Owner’s Manual, that failure

may not be covered under warranty.

Q. What responsibility does my dealer have

under this warranty? A. Each Yamaha generator dealer is expected

to:

1. Check the operation of the generator before sale.

2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date.

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

Q. Is the warranty transferable to second own-

ers?

A. Yes. The remainder of the existing warranty

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

CUSTOMER SERVICE

If your machine requires warranty service, you must take it to any authorized Yamaha generator dealer within the continental United States. Be sure to bring your warranty registration 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 assistance, please write:

YAMAHA MOTOR CORPORATION U.S.A.

CUSTOMER RELATIONS DEPARTMENT

P.O. BOX 6555

Cypress, California 90630

CHANGE OF ADDRESS

The federal government requires each manufacturer to maintain a complete, up-to-date list of all first purchasers against the possibility of a safetyrelated 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 dealer’s 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.

– 3 –

AE00062

WARNING

READ THE OWNER‘S MANUAL AND ALL LABELS BEFORE OPERATING.

AVERTISSEMENT

ONLY OPERATE IN WELL-VENTILATED AREA. 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

MACHINE AU SEC EN TOUTES CIRCONSTANCES.

7NJ-24162-10

8 8 8

8 8

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 DU 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 AU SEC EN TOUTES CIRCONSTANCES.

WARNING

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 electrician. Refer to the owner’s manual.

qet

792-004

792-003

HOT EXHAUST

ENGINE AIR INDEX

(

California onl

)

LEAST CLEAN

MOST CLEAN

NOTE

THE LOWER THE AIR INDEX, THE LESS THE POLLUTION

FOR THE FOLLOWING USE:

THIS ENGINE IS CERTIFIED TO BE EMISSION COMPLIANT

MODERATE

INTERMEDIATE

EXTENDED

CHECK OWNERS MANUAL FOR FURTHER DETAILS

THIS LABEL TO B E REMOVED BY TH E ULTIMATE PURCHASER ONLY!

IMPORTANT ENGINE INFORMATION

ENGINE FAMILY :

zzzzzzzzzzzz

E M

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

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.

YAMAHA MOTOR CO. LTD

zzz-2179R-zz

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

zzz

TYPE

z.zz~z.zz

zzzz

AT NO LOAD

SESAE 10W-30

EMISSIONS COMPLIANCE PERIOD:CATEGORY A (EPA)

LOCATION OF IMPORTANT LABELS

Please read the following labels carefully before operating this machine.

NOTE:

Maintain or replace safety and instruction labels, as necessary.

– 4 –

741-002

741-003

741-005

741- 006

741-007

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

muffler when refuelling.

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.

741-004

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.

– 5 –

741-008a

9 Keep the machine at least 1 m (3 ft) from buildings

741-009

741-067

741-010

741-011

741-012b

or other equipment, or the engine may overheat.

a 1 m (3 ft)

9 Avoid operating the engine with a dust cover.

9 Be sure to carry the generator only by its carrying

handle(s).

1 Carrying handle(s) (shaded)

AE00083

ELECTRIC SHOCK PREVENTION

9 Never operate the engine in rain or snow.

9 Never touch the machine with wet hands or elec-

trical shock will occur.

9 Be sure to ground (earth) the generator.

NOTE:

Use ground (earth) lead of sufficient current capacity.

1 Lead diameter

– 6 –

741-040a

Ground (earth) Lead Diameter:

0.12 mm (0.005 in)/ampere

EX;

10 Ampere → 1.2mm (0.05 in)

AE00088

CONNECTION NOTES

9 Avoid connecting the generator to commercial

power outlet.

9 Avoid connecting the generator in parallel with any

other generator.

1 Correct 2 Incorrect

AE00091

CONNECTION

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

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.

– 7 –

EF1600/EF2600

qw!3 !3!2

o!0

793-015

qw!3 !3!2

o!0

793-016

t!3 !3

793-017

YG2600

AE00101

CONTROL FUNCTION

AE00102

DESCRIPTION

1 Fuel tank 2 Fuel tank cap 3 Fuel cock 4 Air filter cover 5 Spark plug 6 Muffler 7 Choke lever 8 Ground (Earth) terminal 9 Oil filler cap 0 Oil drain plug q Recoil starter w Fuel level gauge e Carrying handles (shaded)

– 8 –

+ 28 hidden pages

Yamaha EF1600 User Manual

INTRODUCTION

CONTENTS

LOCATION OF IMPORTANT LABELS

SAFETY INFORMATION

EXHAUST FUMES ARE POISONOUS

FUEL IS HIGHLY FLAMMABLE AND POISONOUS

ENGINE AND MUFFLER MAY BE HOT

ELECTRIC SHOCK PREVENTION

CONNECTION NOTES

EXTENSION CORD NOTES

CONTROL FUNCTION

DESCRIPTION