YAMAHA GENERATOR
THEORY & DIAGNOSTICS
GUIDE
2009
Yamaha Generator Theory and Diagnostics Guide
©2008 by Yamaha Motor Corporation, U.S.A.
December 2008
All rights reserved. Any reprinting
or unauthorized use
without written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
Specifications, features and options are subject to
change without notice.
08-1169
TABLE OF CONTENTS
GENERATOR INFORMATION AND THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1
Importance of Warranty Registrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Gasoline, Ethanol, Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Yamaha Inverter and Conventional Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
AC Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
12 Volt DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Voltage and Frequency Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Yamaha Generator Inverter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Model Name Clarification YG/EF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Model Introduction Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Extension Cord Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
High Altitude Jetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Special Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
GENERATOR DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2
CONVENTIONAL GENERATOR DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Determining if a Problem is Generator or Engine Related . . . . . . . . . . . . . . . . . . . . . 2-1
THEORY FOR NON-AVR TYPE GENERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
THEORY FOR AVR TYPE GENERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
AVR TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
NON-AVR TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
TROUBLESHOOTING YAMAHA INVERTER GENERATORS . . . . . . . . . . . . . . . . . . . . 2-18
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Generator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Engine Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Throttle Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Electric Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Choke Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
CURRENT MODEL SPECIFICATIONS AND WIRING DIAGRAMS. . . . . . . . . . . . . . . . Section 3
CONSUMER SERIES GENERATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inverter EF1000iS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inverter EF2400iS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Inverter EF2800i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Conventional EF2600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Inverter EF3000iSE / B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Conventional EF4000DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Inverter EF4500iSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Conventional EF5200DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Inverter EF6300iSDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Conventional EF6600DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Conventional EF12000DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
INDUSTRIAL SERIES GENERATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Inverter YG2800i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Conventional YG4000D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104
Conventional YG5200D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
Conventional YG6600D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
Conventional YG6600DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
Generator Information and Theory
GENERATOR INFORMATION AND THEORY
Introduction
The purpose of this manual is to provide training
and information for Yamaha dealers who may not be
familiar with Yamaha Generators. It will help build a
better understanding of how Yamaha Generators
work, basic troubleshooting techniques, and tips for
dealership personnel.
The Importance of Warranty Registration
It is important to warranty register every applicable
Yamaha product sold by your dealership. It is essential for customer satisfaction and insures your customer can receive warranty service from an
authorized Yamaha dealer should the need arise.
Furthermore, warranty repairs performed on a
unit not warranty registered, will not be considered for reimbursement. Warranty registrations
also assist Yamaha with contact information in the
event of a recall or safety related issue.
Gasoline, Ethanol, Propane
Inverter generators differ from conventional generators in many ways. Inverter generators (Yamaha
models with Smart Throttle) do not rely on rpm to
control frequency (Hz). A highly specialized control
unit manages functions such as AC power modification, rpm, circuit breaker protection, overload warning, and electrical output. Inverters do not need to
run at 3,600 rpm as most use a 3-phase multi-pole
stator. The inverter can produce more electricity with
fewer revolutions versus a single-phase conventional generator. Typically, multi-pole coils work in
conjunction with numerous permanent magnets to
produce higher output at a lower rpm. Less revolutions means higher fuel economy at lower outputs
and quieter operation.
Inverter generators also provide very stable and
clean power. The AC power produced by the multipole coil is rectified into DC power – the control unit
then inverts the DC power back into AC power. This
final inversion creates clean, high-quality electricity.
In most cases, the electricity produced by a Yamaha
Inverter Generator is cleaner than most commercial/
residential power.
All models of Yamaha generators run on regular
gasoline. Up to 10% ethanol is acceptable for running conditions. However, ethanol tends to attract
moisture which will lead to poor performance, so it
should not be used when storing a generator for
more than a few days.
Currently, there are no propane conversion kits
available that Yamaha Motor Corporation, U.S.A.
supports. Further, Yamaha recommends against the
use of any aftermarket generator propane conversion kits.
Yamaha Inverter and Conventional Generators
The AC power created by conventional generators is
known as “raw” power. The electricity produced by
the stator (coils) and rotor (magnets) is delivered to
the outlet without modification of the AC sine wave.
In addition, conventional generators must run at
3,600 rpm in order to maintain the required 60 Hz
cycle. The power generated by a conventional generator depends on a constant engine speed. Any
fluctuation of rpm will create peaks (spikes) and valleys in the AC sine wave. Conventional generators
rely on large, heavy stators and rotors, which means
a heavier generator. Conventional generators are
typically less fuel efficient at low output levels
because they must run at 3,600 rpm at all times.
*
HIGH QUALITY
AC
*PWM: Pulse Width Modulation is very clean and
stable output with a waveform distortion ratio of
2.5% or less. This low distortion ratio means the
output is cleaner than most commercial / residential
power, making it safe to run sensitive computer
equipment, televisions, and microchip-controlled
power tools.
1-1
Yamaha Generator Theory & Diagnostics Guide
Air intake Fuel tank cap Fuel gauge
Recoil starter Control panel Service hatch Exhaust MF Battery Service hatch
Main switch Economy control switch DC output AC receptacles
Fuel pet cock Choke knob Oil warning lamp
Output indicator
Over load indicator
USA specification
⎧⎪⎨⎪⎩
Yamaha inverter generators use a microcomputer-controlled sine wave inverter. Most inverter generators are
in a soundproof case, and designed in response to the diverse needs of the market today.
The Yamaha inverter generator supplies high quality electricity equivalent to household power supply.
NOTE: The EF3000iSE is used in this introduction section for explanation purposes.
Fuel petcock
1-2
Generator Information and Theory
Stepping motor
Power Generation
Stage 1 The rectifier circuit converts three- phase
AC into DC and it maintains stable DC
voltage using a constant voltage circuit.
Stage 2 The constant voltage DC current is
stored in a condenser.
Stage 3 The PWM, Pulse Width Modulator,
inverter circuit generates a stable sine
wave AC current.
Stage 4 The filter circuit further smoothens the
sine wave of the AC current and reduces
electrical noise.
Protective functions:
■ Overload (over current) protection device
The control unit has similar function to conven-
tional NFB (no fuse breaker). When the output
current exceeds a specified amperage, AC output is interrupted.
■ Overheat protection
When the internal temperature of the control
unit becomes abnormally high, AC output is
interrupted.
■ Over-voltage protection device
AC output is interrupted when excessive current
flows into the generator from an outside power
source causing voltage to rise in the control
unit.
■ Throttle motor (stepping motor)
The throttle motor receives pulses from the con-
trol unit and opens or closes the throttle valve
approximately 0.7° per pulse.
STEPPING MOTOR
Functions of the Electronic Governor
The inverter control unit is preprogrammed with the
ideal engine speed settings in relation to electrical
current output. It uses these settings as a cross-reference with the detected current output to control
the throttle motor (and consequently the throttle
valve) to adjust engine speed to an optimum level.
Therefore, the engine speed will always be at the
appropriate level according to the load on the system.
With an inverter generator, even if the engine
speed changes it has no effect on the output
frequency.
Other Functions of the Control Unit:
Throttle Control – Control unit commands the throttle
motor to adjust engine speed automatically in accordance with the amount of the electrical consumption.
Electronic Governor
An electronic governor takes the place of a conventional mechanical governor, and opens and closes
the carburetor throttle valve electrically.
Components and functions:
■ Inverter control unit
The control unit constantly monitors AC output
The electronic governor system is maintenance-free
as it cannot be adjusted externally.
THROTTLE
CONTROL
ENGINE rpm
DETECTOR
and adjusts the throttle motor to produce the
necessary engine speed.
1-3
Yamaha Generator Theory & Diagnostics Guide
Fuel tank
Control unit
Recoil starter
Battery
EF3000iSE/EF3000iSEB
Control unit
AC OUTPUTS
There are two levels of output available from Yamaha
generators:
1. Peak Output (short period of time).
2. Rated Output (continuous duty).
In normal operation of course, these levels would
merge. The built-in Thermal or Nonfuse Breakers
(NFB) are designed to protect against harmful overloads, while allowing for these different levels. The
length of time the breaker allows the generator to
produce a particular level without interrupting the
current flow varies. This flexibility permits the generator to be used for a wide variety of applications:
1. The stated peak output is the amount of current that can be utilized for short time periods
before the NFB disconnects the output. This
output level allows for jobs of short duration,
requiring maximum output (tool startup).
2. The rated output is the amount of current the
generator can supply for continuous operation.
12 Volt DC Output
The DC output is intended only to charge a 12-volt
battery. If any 12-volt devices should be connected
to a 12V battery and never to the 12V plug on the
generator. It is possible that a device could be damaged if it is connected directly to a generator.
The DC output is controlled only by the capability,
condition, and state of charge of the battery.
Voltage and Frequency Standards
In the U.S., standard commercial electricity is delivered at 110~120 V AC, and 220~240 V AC. The
electrical frequency standard is 60 cycles per second (60 Hz).
Reference information:
Ferrite magnets are magnetically stable and have a
strong coercive force and so do not become demagnetized. While they have excellent corrosion resistance, they are also brittle due to the way they are
produced. Great care must be taken when assem-
bling them as jarring or shocks of force can
adversely affect their efficiency and/or cause
breakage.
EF3000iSE/EF30 00iSEB
Control Unit
The control unit is a sealed unit.
Functions:
AC power generation
Electronic governor (throttle control)
Economy control program
Self-protective function
Over current
Over voltage
High temperature
Multi-pole Alternator Features
Used in Inverter Generators
The combination of ferrite magnets in the rotor and
multi-pole stator provides a compact and high performance alternator.
High-frequency multi-pole alternator features:
16-pole rotor
24-pole stator coil
3-phase AC power generation
CONTROL UNIT
1-4
Section
Control unit
*
Condenser Winding Sine Wave
Condenser Winding Sine Wave
Inverter Sine Wave
Yamaha Generator Inverter System
The control unit and multi-pole alternator cooperate to generate AC output. The inverter, controlled by a 16-bit
microcomputer, is a Pulse Width Modulation (PWM) sine wave inverter.
1. The generator’s output frequency remains unchanged even when the engine speed varies.
2. The output voltage is stable.
3. The output waveform is a sine wave with a distortion ratio of less than 2.5%, equivalent to household
electricity.
PRINCIPLES OF POWER GENERATION WITH AN INVERTER PORTABLE GENERATOR
*An alternator that uses highly efficient ferrite magnets generates three-phase AC.
•120VModel:AC135to225V,300to550Hz
•230VModel:AC260to488V,300to550Hz
CONVENTIONAL SINE WAVE
INVERTER SINE WAVE
1-5
Yamaha Generator Theory & Diagnostics Guide
Resistance 250Ω Terminal:F3-1, 3-5, 3-2, 3-4
500Ω Te rminal: 1-5, 2-4
Throttle valve position:
During assembly:Close
During engine starting:Open
Resistance 250Ω Terminal:F3-1, 3-5, 3-2, 3-4
500Ω Te rminal: 1-5, 2-4
Throttle valve position:
During assembly:Close
During engine starting:Open
Economy Control Characteristics
Throttle Motor
Caution during resistance measurement:
Do not allow the lead wire of the tester to touch the
next terminal when measuring the resistance
between terminals.
Caution during assembly:
To prevent damage to the throttle valve when reassembling the carburetor, re-install the carburetor
with the throttle valve fully opened.
If the engine is difficult to start after the carburetor is installed, fully open the throttle valve by
hand and then start the engine.
2. When changes in voltage cannot be accepted.
3. When charging batteries.
Economy Control Characteristics
of an EF3000iSE/B
Economy switch ON: 2800 rpm (with no load)
Economy switch OFF: 3550 rpm
The engine will run at 2800 rpm with economy
switch turned on, if the electrical consumption is
below 1/4 of its rated output.
Economy Control Operation and Features
Because output frequency of an inverter generator
is unrelated to the engine speed, it is possible to use
a wide range of engine speed.
It also becomes possible to use low engine speed to
meet a low electrical consumption.
The control unit commands the throttle motor built
into the carburetor to control the throttle valve, which
gives it the ability to continuously control the engine
speed, which in turn makes the economy control
system possible.
However, the economy control switch should be
turned off in case of the following occasions:
1. When operating an electric motor, such as
water pump, which requires a large starting current.
When a light and electric motor are connected to the
generator at the same time, turning one of the
devices on and off causes a change in voltage and
could have an adverse effect on the other device.
In these kinds of cases, first turn the economy
switch off before use.
Throttle valve operation:
■ The throttle valve is fully opened when the
engine is not running.
■ When the engine is started with no load, the
throttle valve will be set in an almost completely
closed position as soon as the engine is started.
(When the economy switch is “ON,” it will be in
a position to maintain 2800 rpm.)
■ The engine speed will be adjusted according to
the requirements of the load on the system.
■ The throttle stops at the fully opened position
when the engine is turned off in order to prepare
for the next attempt to start the engine.
In temperatures of 0° or below, the engine will automatically run at 3550 rpm for three minutes for
warming up purposes, even when the economy
control switch is turned ON.
1-6
Generator Information and Theory
Continuous Running Time
EF3000iSE is able to run for 20.5 hours with 1/4
load with fuel tank full, when economy control switch
is on.
With rated load: 8.0 hours
With 1/4 load: 20.5 Hours
Refer to Section 3 for model specific run times and
rated load information.
The frequency variation of Yamaha inverter generators is less than 0.1%.
Voltage Variation
The output voltage with no load is approximately
10% higher than rated voltage for a case of conventional synchronous type generators to achieve the
rated voltage when full rated load is connected. Thus
the voltage variation occurs due to the change in
engine speed and the influence of the internal resistance.
However, adapting an inverter system, the voltage
variation can be minimized, because the output voltage cannot be influenced directly from engine
speed.
Frequency Variation
Conventional synchronous generators have an
engine speed with no load set at approximately 6%
higher than rated engine speed (3600rpm for 60 Hz)
to maintain rated frequency when full rated load is
applied. This is the reason why no-load frequency is
slightly higher than rated frequency.
However, adapting an inverter system, which generates genuine sine wave electricity, the frequency
variation of an inverter generator is not influenced by
the engine speed. Therefore, an inverter generator
provides constant AC output frequency even if the
load changes which is equivalent quality to the commercial power supplies.
The voltage variation of Yamaha inverter generators is smaller than 3%.
The waveform distortion rate of Yamaha inverter
generators is smaller than 2.5%.
1-7
Yamaha Generator Theory & Diagnostics Guide
Instantaneous Frequency Fluctuation &
Instantaneous Voltage Drop
■ Momentary frequency fluctuation:
The frequency and voltage fluctuates momen-
tarily when the load is altered if the engine cannot keep up with the load changes in the case
of conventional synchronous generators.
In contrast the momentary frequency fluctuation
of Yamaha inverter generators is as stable as
the commercial power source with this new
inverter system.
Electronic Breaker
As opposed to the non-fuse breaker (NFB) used in
synchronous type generators, Yamaha inverter generators use an electronic breaker circuit housed in
the control unit. When output from the control unit
exceeds a specific limit, output is automatically interrupted to protect the generator from damage.
The control unit is designed to continuously monitor
the output current for overloads, and if the current
overload continues longer than a specified time,
output is interrupted.
The frequency fluctuation rate of Yamaha inverter
generators is less than 0.1%.
■ Momentary voltage drop:
However, the momentary voltage drop occurs,
when large electric load is turned on. This is
caused by the fact that the electric energy
stored in the condenser runs short momentarily
until the engine speed picks up to sufficient
engine speed to compensate the energy shortage in the condenser. The ratio of such momentary voltage drop and the rated voltage is
defined as momentary voltage drop rate. The
momentary voltage drop rate of Yamaha inverter
generators is usually less than 20%. Naturally,
the smaller the load capacity is applied, the
smaller the momentary voltage drop becomes.
In case of incandescent lamps, large amounts
of current flow the moment it is switched on. The
rush current may be as large as 10 times the
rated current of the lamp. Therefore, when a
large wattage incandescent lamp(s) are switched
on, the momentary voltage drop is greater.
When using induction motors or similar devices
(such as underwater pumps) which require a large
starting current with the generator, the current will
not be interrupted even if the starting current
exceeds several times the generator’s rated output.
Only when the large over current continues longer
than a specified time, the control unit will interrupt
the circuit, and in this way it resembles a mechanical NFB.
The engine must be stopped and power interrupted
to the control unit in order for the system to reset
after the electronic breaker has activated.
NOTE: If a device’s power switch is ON when it is
connected the generator and the generator is subsequently started, the device may unexpectedly
activate or start up as a result, creating a potentially
dangerous situation.
1-8
Generator Information and Theory
Control Panel
Refer to Section 3 for model specific control panel
diagrams.
Indicators
Overload Warning Lamp
During power generation, if a problem occurs with a
connected device, there is an overload, or the
inverter control unit overheats, the electronic breaker
will be activated and interrupt power output to protect the generator and/or connected devices.
■ When the electronic breaker operates:
The engine continues to run, but the control unit
stops output
The output indicator (green) turns off
The overload indicator (red) turns on
■ When the overload warning light turns on:
Stop the engine.
Verify the required load of the connected device,
and reduce to the rated load of the generator if
necessary. Verify whether or not there is a problem with a connected device. (A possible cause
of excessive current drain.)
Check for foreign matter in the cooling air inlet
and areas around the control unit which could
block incoming air.
Output Indicator
When the generator is running normally and generating power, this indicator is lit green.
When using a device which requires a large starting
current, the overload warning light (red) and output
indicator (green) will temporarily light simultaneously. This operation is normal.
After the connected device has started up, the overload warning light (red) will turn off, while the output
indicator (green) will continue to be lit.
Oil Warning Lamp
As with all Yamaha generators, the engine will shut
off automatically when the oil level decreases to a
specified level.
When this happens and the recoil starter is pulled,
the engine will not start and the oil warning light will
turn on.
■ To return the generator to normal output
operation:
Temporarily stopping the engine and re-starting
automatically resets the system to its original
state. (The system cannot be reset unless power
to the control unit is interrupted by stopping the
engine.)
1-9
Yamaha Generator Theory & Diagnostics Guide
Rotor Ass’y
Muffler
Cooling fan
Generator
cooling
air inlet
Flow of cooling air over generator and muffler
Controller
Cooling air inlets
Battery
Cooling air inlets
Recoil starter
Muffler
Generator fan
Generator cooling air inlet
Overall flow of cooling air
Control unit
Intake box
Cooling
air inlets
Fan case
Cooling fan
Flow of cooling air over generator and muffler
Rotor Ass’y
Muffler
Cooling fan
Generator
cooling
air inlet
Flow of cooling air over generator and muffler
Rotor Ass’y
Muffler
Cooling fan
Generator
cooling
air inlet
Flow of cooling air over generator and muffler
Control unit
Intake box
Cooling
air inlets
Fan case
Cooling fan
Flow of cooling air over generator and muffler
Ventilation
Be aware of the surroundings where generators are being used. Three (3) feet of clear space is necessary for
safe operation. Adequate ventilation is also necessary, as the generator’s engine needs fresh air for the intake,
and the exhaust must be safely vented. Refer to the Owner’s Manual for complete information.
Lubrication System
The engine units of all Yamaha conventional and inverter generators use a splash type oiling system.
Cooling System
The centrifugal fan equipped on the rotor performs forced air cooling of the system over the path listed below.
Each part of the system is therefore continuously kept at a stable operating temperature with only a single
fan.
Cooling systems will vary from one model to another. The EF3000iSE is shown here as an example. Refer to
the Owner’s or Service Manual for model specific information.
• Coolingairpath
• Controlunitcover
• Controlunit
• Alternator
• Engine(cylinder)
• Muffler
Generator Storage
To prepare a Yamaha generator for storage follow these basic
procedures:
• The carburetor float bowl should be emptied using the
float bowl drain screw located on the float bowl.
• Thefueltankshouldbefullandcontaintheproperamount
of a fuel stabilizer.
• The unit should be covered and stored in a cool dry
place.
• RefertotheOwner’sorServiceManualforcompletestorage information.
1-10
Generator Information and Theory
Rectifier
G/Y
R/W
B/W
B
B
R
R
RR
R
M
R
R
R
B
B
L
L
L
L
B
R
R
R
R R
R
R
G
GG
O
O
O O
O
O
OO
O
O
O
O
B/W
O
Y
Y
Y
Y
Y
Y
Y
Y
YYYY
YY
L
LL
W
W
W
W
B
B
W
W
R/W
G/Y
G/Y
G/Y
Gy
G/Y
G/Y
G/Y
G/Y
B/W
B/W
B/W
B/W
B/W
R/W
R/W
B/W
B
B/W
B/W
B/W
R
R
R
R
R
O
Y
R
R
B
B
B
B
R
Br
Br
Br Br
Br
Br
Br
Br
OFF
ON
START
R
R
@2
@3
@4
t
!9
!6
!5
i
!3
!2
!4
!1
!0
o
u
u
y
@5
1 Main coil
2 Sub coil
3 DC coil
4 DC rectifier
5 Control unit
6 AC pilot light
7 AC receptacle
8 Ground (Earth) terminal
9 Economy control switch
0 Overload indicator light
q DC receptacle
w DC protector (breaker)
e Engine switch
r Oil warning light
t Speed limiter assenbly
y Oil level gauge
u T.C.I. unit
i Spark plug
o T.C.I. magneto
p Stepping motor
a DC-DC converter
s Rectifier
d Battery
f Starter relay
g Starter motor
(+)
(–)
(~)
(~)
Polarity of rectifier 7VU-87105-00
Rectifier
G/Y
R/W
B/W
B
B
R
R
RR
R
M
R
R
R
B
B
L
L
L
L
B
R
R
R
R R
R
R
G
GG
O
O
O O
O
O
OO
O
O
O
O
B/W
O
Y
Y
Y
Y
Y
Y
Y
Y
YYYY
YY
L
LL
W
W
W
W
B
B
W
W
R/W
G/Y
G/Y
G/Y
Gy
G/Y
G/Y
G/Y
G/Y
B/W
B/W
B/W
B/W
B/W
R/W
R/W
B/W
B
B/W
B/W
B/W
R
R
R
R
R
O
Y
R
R
B
B
B
B
R
Br
Br
Br Br
Br
Br
Br
Br
OFF
ON
START
R
R
@2
@3
@4
t
!9
!6
!5
i
!3
!2
!4
!1
!0
o
u
u
y
@5
1 Main coil
2 Sub coil
3 DC coil
4 DC rectifier
5 Control unit
6 AC pilot light
7 AC receptacle
8 Ground (Earth) terminal
9 Economy control switch
0 Overload indicator light
q DC receptacle
w DC protector (breaker)
e Engine switch
r Oil warning light
t Speed limiter assenbly
y Oil level gauge
u T.C.I. unit
i Spark plug
o T.C.I. magneto
p Stepping motor
a DC-DC converter
s Rectifier
d Battery
f Starter relay
g Starter motor
DC 12V Output
DC output is provided on Yamaha inverter generators exclusively for battery charging.
Rated output: DC 12V ~ 12A (12V ~ 8.3A for Canada)
DC 12V circuit is entirely separated from AC circuit.
Economy control switch must be turned off while charging a battery, as the engine speed 3550 rpm is required
to generate rated DC-output.
The total electric consumption of both the AC and the DC output should not exceed the total rated output of
the generator, which is 2800 Va, when both output are used together.
Rectifier (for DC output)
1-11
Yamaha Generator Theory & Diagnostics Guide
WARNING
WARNING
Battery Charging
■ Conditions of use of the DC power supply
■ Charging a 12V battery
Do not use for other than charging a 12V
battery.
The time taken to charge a battery depends on how
the battery is discharged. Charging is complete
when the specific gravity of the battery is 1.26~1.28.
Check the specific gravity in every hour or so.
A 40AH battery of a compact car which is half discharged will be almost fully charged in about 3
hours. Be sure to check the level of the electrolyte.
Do not take energy from the battery nor run the
starter when the battery is being charged. This could
cause a large current to flow through the generator
coil, burning it.
■ Precautions for charging the battery
The battery will produce a flammable gas. The
wrong handling might result in explosion or
serious injuries. Be sure to observe the following when charging a battery.
FIRST-AID PROCEDURES: If your skin or clothes
come in contact with the electrolyte, wash them
with a large amount of water immediately. If it
enters your eyes, wash with a large amount of
water and consult the doctor immediately.
• Whenhandlingabattery,keepgoodventilation and keep electric sparks, like from
short-circuit, away. Also, keep fire away.
Explosion might happen because a flammable gas occurs from the battery.
• The battery electrolyte is diluted sulfuric
acid. If it comes in contact with your eyes or
skin, the affected part will be burnt. If it
should happen, wash the part with a large
amount of water for at least 15 minutes and
consult the doctor immediately.
1. Keep fire and electric sparks away. Explosion
might happen.
2. Secure a good ventilation where the battery
is charged. Otherwise, explosion might happen.
3. Be very careful to handle the electrolyte
(diluted sulfuric acid). It will burn anything,
so keep it away from your eyes, skin and
clothes.
4. Before charging a battery, remove all cords
connected to the battery, doing it first from
the negative side. When reconnecting, do
the positive side first. If you do it incorrectly,
a short-circuit could result.
1-12
EF2800i AC-CDI
The Yamaha EF2800i Inverter generator is the only
generator in the Yamaha line-up to use an AC-CDI.
A CDI unit which uses AC power to charge the condenser is referred to as an AC-CDI.
Taking the low voltage power generated by the
charge coil (which is wound around a single stator
core in the multi-polar alternator), a voltage booster
circuit boosts the voltage in the CDI in order to
charge the condenser. In a typical CDI system, voltage of approximately 200~400 volts is generated by
the charge coil.
The advantages are the charge coil can be made
both lighter and smaller. Also a heavier wire can be
used for the charge coil to increase its reliability.
An overrun limiter is incorporated into the EF2800i’s
AC-CDI unit.
The ignition spark is regulated to prevent engine
speed overrun when the engine speed exceeds
4500 rpm.
Generator Information and Theory
A new oil warning system was designed to match
the new CDI system, while maintaining the same
function of the conventional oil warning system.
1-13
Yamaha Generator Theory & Diagnostics Guide
The EF1000iS
Exclusive to the EF1000iS, the double-coil system is
a unique design that adds to the main coil a second
coil specifically for running at lower rpm. Increasing
the number of coils in this second low-speed coil
enables it to generate optimum electricity when the
engine is running at lower rpm. When the engine
rpm increases, however, these extra coils become
unwanted resistance that reduced generating efficiency. Thus, a system has been adopted that automatically selects the right coil in relation to the
engine rpm; the low speed coil becomes the main
generating coil at low rpm and the main coil from
middle to high rpm. This is a Yamaha-exclusive technology that might be called a dual-stage system to
accommodate low and middle range rpm. The result
is a generating system that can provide optimum
electricity supply that is stable even at low rpm and
thus run with less noise and better fuel economy.
EF1000iS
1-14
Generator Information and Theory
Control Unit
Control Unit
DC-DC converter
Power Boost Technology
EF3000iSEB is equipped with a DC-DC converter, which supplies supplemental electric current to the inverter
control unit to boost up the generator output by an additional 500 watts for maximum 10 seconds. This feature
is exclusive on the EF3000iSEB.
DC-DC Converter (Power Boost Technology)
The DC-DC converter is an electrical device to step
up DC voltage. The EF3000iSEB DC-DC converter
steps up the battery voltage from 12 volts to 190
volts.
DC-DC converter is automatically activated to
increase generator output when the AC output current exceeds 20 amps and the voltage at the condenser inside the control unit drops down to below
190 volts.
The power source is a 12-V battery installed in the
generator to operate the starter motor. DC-DC converter works for maximum 10 seconds, only when a
large amount of starting current is needed and
increases maximum output of generator from 3000
VA to 3200 VA temporarily.
Specifications of DC-DC converter
1. DC input 12V Battery
2. DC output DC190V
3. Rated DC current 2.53 A
1-15
Yamaha Generator Theory & Diagnostics Guide
Green LED Red LED Designation
ON OFF Standby mode
Blink OFF Output (for 10 seconds maximum)
OFF Blink For 10 seconds after shutdown
OFF ON Alarm mode
⎫⎪⎪⎪⎪⎬⎪⎪⎪⎪⎭
Overload Indicator Lamp:
The DC-DC converter is turned on automatically,
when the generator output exceeds over 180% of its
rated load to boost generator output to assist the
starting current of the load, such as an air conditioner.
When the DC-DC converter is turned on automatically, the generator is obviously overloaded, thus the
overload indicator lamp blinks quickly with 0.5-second interval for 10 seconds. And the lamp blinks
slowly with 1-second interval for 3 minutes and 50
seconds. During this period, the DC-DC converter is
prevented from rebooting to prevent the battery from
over-discharged.
Designation of LED Indicators:
DC-DC converter unit is equipped with two indicator lamps (LED) on the unit. When the DC-DC converter is
activated automatically, indicator lamps are lit or blink to designate the state of the system. The designations
of indicator lamps are listed in the table below.
NOTE: The red LED turns ON and interrupts DC-DC converter output automatically to protect the component,
when any of the abnormal operating conditions is detected, and returns to normal operation automatically as
soon as the abnormality is recovered.
Abnormal conditions are:
1. Too high temperature in the component
2. Too low battery voltage, below 9.5V
3. Too high battery voltage, over 18V
1-16
TCI Ignition System
TCI ignition system is equipped with a speed limiter
function.
Speed limiter: 4500 rpm
Generator Information and Theory
Oil Warning System
The oil-warning unit is built in the speed limiter unit.
The oil-warning switch is installed in the crankcase.
When the engine oil level drops below the specified
level, the ignition system is grounded and the engine
will be automatically stopped. This function prevents
the engine from serious damage.
The ignition coil and TCI unit is a single built-in unit,
while the speed limiter unit is a separate component
installed in the control box.
The oil-warning lamp turns on by attempting to start
the engine so as to warn the operator that the
engine oil should be replaced or refilled.
1-17
Yamaha Generator Theory & Diagnostics Guide
1
1
2
3
4
Auto-decompression System
All Yamaha generators are equipped with an autodecompression system to facilitate engine starting
operation.
While the engine is stationary or running at very low
speed, a pin provided in the camshaft is projected
above the basic circle of exhaust cam lobe.
The pin, consequently, pushes the valve lifter causing the exhaust valve to stay open, thus compression pressure is released.
When the engine speed becomes faster, the decompression weight, which holds the pin in the position,
is thrown out and the pin moves back, thus the
engine can be started as the exhaust valve functions normally.
Muffler Cleaning
1. Turn the engine switch to the “STOP” position to
stop the engine.
2. Loosen the bolt ① and remove the muffler cap
and muffler screen.
3. Remove the carbon deposits on the muffler cap
②, the muffler screen ③ and the spark arrester
④ using a wire brush.
4. Install the muffler screen ③, the muffler cap ②
and the spark arrester ④.
1-18
Battery Initial Charging Procedure
Generator Information and Theory
1. Cases in which Charging of a New Battery is Required (Initial Charging)
Although the Sealed Motorcycle MF Battery can be used after it is filled with electrolyte, it may not be able
to start a motor in cases like those indicated in the table below. In such cases, perform initial charging
before using the battery. Furthermore, initial charging is not required if the terminal voltage (*1) ten minutes
after filling with electrolyte is not less than 12.5V.
2. Initial Charging Procedure
Although the procedure for initial charging of the Sealed Motorcycle MF Battery is based on the charging
procedure indicated on the top of the battery, it is recommended to determine the duration of initial charging based on the terminal voltage.
YT4L-BS
NOTE:
a. Terminal Voltage
Use a digital voltmeter (or voltmeter of class 1 accuracy or better) to mea-
sure battery terminal voltage. Continue to measure terminal voltage in the
same manner.
b. Standard Current Charging Time
Set the standard current to the current value indicated as the standard
charging current on the top of the battery.
If the terminal voltage is less than 11.5V, internal resistance may be high
due to long-term storage, charge the battery by following the procedure.
It is necessary to adjust the voltmeter so that the standard current flows
after five minutes. Charging a battery that has become excessively discharged to less than a battery terminal voltage of 11.5V charging may not be possible at the normal charging voltage (16~17V) due to high
internal resistance. In such cases, initially increase the charging voltage (maximum 25V), and then charge
for about 5 minutes. (The battery must be replaced if there is no change in the voltmeter reading (A) after
5 minutes.) Since excessively high current will flow once the current begins to flow, always make sure to
adjust the voltage of the charger so as not to exceed the standard current. This initial charging procedure
can be performed automatically by using the Yuasa MF Battery Charger (such as model PS1512).
3. Assessing Battery Performance After Initial Charging
Assessment of battery performance following charging of the Sealed Motorcycle MF Battery should be
made by measuring battery terminal voltage after allowing the battery to stand for about 30 minutes following completion of charging.
NOTE: Use of the Yuasa Model BM-310 Battery
Tester lets you make a more accurate assessment of battery performance.
1-19
Yamaha Generator Theory & Diagnostics Guide
WARNING
No Fuse Breaker (NFB)
Sometimes called a Non Fuse Breaker, this device
acts like a fuse to interrupt power in the event of a
sudden spike or surge in current. Unlike a fuse, however, the NFB can be reset.
Electronic Breaker
An electronic circuit breaker automatically cuts off
the current when the output voltage exceeds the
maximum capacity.
Smart-Throttle
Because output frequency of an Inverter Generator
is unrelated to engine rpm it becomes possible to
utilize a wide range of engine rpm. This feature
helps quiet running by choosing the minimum
engine rpm necessary for the actual electrical load.
A double coil system such as on the EF1000iS
makes possible a higher output even at a low rpm
setting. Smart Throttle ONLY applies to inverter
models that have an electronic throttle servo motor
to control engine speed.
Economy Control (also called Economy Idle)
Conventional generators, and in some cases inverter
generators use economy control / idle. This function
causes the unit to idle down when a load is not present.
Ground Fault Interruption (GFI)
Shuts down the power when a fault to ground is
detected. A device that interrupts the power flowing
through a GFI receptacle when a proper ground/
earth ground is not present or a short were to take
place - to prevent electrocution
Right Sizing and Power Management:
Determining Your Consumer Series Customer’s
Energy Needs
When selling a generator, it is important to select
one that is capable of meeting the energy requirements of the customer. Match the rated output of
the generator to the maximum anticipated power
demand.
This section will assist in estimating the power
requirements, so the purchase will satisfy the needs.
Make a list of the appliances and devices or tools
that you expect to operate, as well as the approximate power requirements for each device.
Electrocution, severe personal injury or death
can occur: Do not connect any generator to any
building’s electrical system unless an isolation
switch has been installed by a licensed electrician. Refer to the Generator Owner's Manual.
Property damage can occur: Do not connect any
generator to any building's electrical system
unless an isolation switch has been installed by
a licensed electrician. Refer to the Generator
Owner's Manual.
Take It Step-By-Step
Follow these steps when determining your energy
needs:
1. Identify the wattage requirements for the tools
and appliances that you want to power. The
power requirements for the tool or appliance are
found on its identification plate or in the Owner's
Manual. If the power requirement is given in
amps, multiply the amps times volts to derive
the required watts.
Amps x Volts = Watts
2. Add up the required watts of all the tools and
appliances you expect to operate simultaneously.
3. The total watts derived in step 2 equals the size
Yamaha generator you need. These three simple steps will “size” a generator. However, you
must keep in mind that devices with electric
motors require at least 2-3 times their running
wattage for start-up power. This multiplier varies
with the age, type, and condition of the electric
motor. A good “rule of thumb” to use for this is
Horse Power multiplied by 932 usually equals a
motor’s starting wattage (HP x 932 = SW).
The chart on the next page lets you immediately
add up all of the appliances you will most likely utilize:
After making the list, estimate the highest demand
on the generator under the “worstcase” conditions.
With this figure, determine the appropriate model
Yamaha generator for your particular needs.
1-20
Generator Information and Theory
CONSUMER GENERATOR WORKSHEET
Running
Wattage
Requirements*
HEATING/COOLING:
Furnace Fan, gas
or fuel oil furnace
1/8 horsepower 300 500
1/6 horsepower 500 750
1/4 horsepower 600 1000
2/5 horsepower 700 1400
3/5 horsepower 875 2350
Central
Air Conditioner
10,000 BTU 1500 2200
20,000 BTU 2500 3300
24,000 BTU 3800 4950
32,000 BTU 5000 6500
40,000 BTU 6000 6700
HEATING/COOLING: SUB-TOTAL:
KITCHEN
Refrigerator, Average 600 2200
Dish Washer Cool Dry
Dish Washer Hot Dry
Clothes Dryer - Gas 700 1800
Clothes Dryer Electric
Microwave Oven,
1000W
Washing Machine 750 2300
Coffee Maker 1000 0
Toaster 2-slice 1100 0
Toaster 4-slice 1650 0
Electric Skillet 1500 0
Electric Range
6-in. element
Electric Range
8-in. element
Freezer 2500 2200
KITCHEN SUB-TOTAL:
BATHROOM
Hair Dryer 1500 watt 1500 0
Iron 1200 0
BATHROOM SUBTOTAL:
700 1400
1450 1400
5750 1800
1500 1650
1500 0
2100 0
Additional
Starting
Wattage
Requirements
Totals
Running
Wattage
Requirements*
APPLIANCES
Lights- Wattage Actual:
VCR 50 0
Heating Pad 65 0
Radio 100 0
Television - Black &
White
Television - Color 300 0
Dehumidifier 400 0
Electric Blanket 400 0
Garage Door Opener 1/4HP
Garage Door Opener 1/3HP
Well Pump - 1/3 hp 750 1400
Well Pump - 1/2 hp 1000 2100
Sump Pump - 1/3 hp 800 1300
Sump Pump - 1/2 hp 1050 2150
Vacuum Cleaner Standard
Vacuum Cleaner Deluxe
APPLIANCES SUB-TOTAL:
*Running wattage values are for estimation only.
100 0
550 1100
725 1400
800 0
1100 0
Additional
Starting
Wattage
Requirements
Totals
1-21
Yamaha Generator Theory & Diagnostics Guide
CONSUMER APPLICATION TABLE
APPLICATION / WATTS*
VCR 50 • • • • • • • • • •
75 Watt Light Bulb (Single) 75 • • • • • • • • • •
Radio 100 • • • • • • • • • •
Television (B&W) 100 • • • • • • • • • •
Window Fan 250 • • • • • • • • • •
Blender 300 • • • • • • • • • •
3/4" Drill 350 • • • • • • • • • •
Television (Color) 350 • • • • • • • • • •
RV W/NO Appliances
On 400~600
RV Refrigerator 600 • • • • • • • • • •
650 Watt Microwave Oven 1000 • • • • • • • • •
Washing Machine 750 • • • • • • • • • •
Jigsaw 800 • • • • • • • • • •
Coffee Maker 850 • • • • • • • • • •
Electric Weed Trimmer 1000 • • • • • • • • • •
Router 1000 • • • • • • • • • •
Belt Sander 1000 • • • • • • • • • •
2-Slice Toaster 1100 • • • • • • • • • •
Vacuum Cleaner 1100 • • • • • • • • • •
Disc Sander 1200 • • • • • • • • • •
Chain Saw 1200 • • • • • • • • • •
13,500 btu
RV Air Conditioner 1200
Space Heater 1300 • • • • • • • • •
RV Water Heater 1500 • • • • • • • • • •
1000 Watt Microwave 1500 • • • • • • • • • •
1500 Watt Blow Dryer 1600 • • • • • • • • • •
Electric Range
(One Element) 1500
4-Slice Toaster 1650 • • • • • • • • • •
7 1/4" Circular Saw 2000 • • • • • • • • • •
Disc Grinder 2000 • • • • • • • • • •
Air Compressor 2000 • • • • • • • • • •
Air Conditioner
(10,000 BTU) 2500**
Refrigerator / Freezer 250 • • • • • •
Water Heater 3000 • • • • • •
Well Pump 4500 • • •
EF1000IS
EF2400IS
EF2600
EF2800I
EF3000ISE
EF3000ISEB
EF4000DE
EF5200DE
• • • • • • • • • •
• • • • • • • • • •
• • • • • • • • • •
• • • • • •
*Running wattage values are for estimation only.
EF6600DE
EF12000DE
•
•
**Capable of running most 13,500 btu air conditioners.
1-22
Generator Information and Theory
Determining Your Industrial Series Customer’s
Energy Needs
INDUSTRIAL APPLICATION TABLE
Inverter
Series
APPLICATION* Watts
3/4" Drill 350 • • • • •
3-1/4" Planer 500 • • • • •
Reciprocating Saw 500 • • • • •
Airless Sprayer 1/3 HP 600 • • • • •
1/2" Drill 700 • • • • •
Electric Weed Trimmer 1000 • • • • •
Rotary Hammer 1000 • • • • •
Router 1000 • • • • •
Belt Sander 1000 • • • • •
6-1/2" Planer 1200 • • • • •
Disc Sander 1200 • • • • •
Electric Chain Saw 1200 • • • • •
Space Heater 1300 • • • • •
Demolition Hammer 1500 • • • • •
10" Miter Saw 1500 • • • • •
16" Beam Saw 1500 • • • •
14" Cut-off Saw 1500 • • • • •
9" Disc Grinder 1800 • • • • •
12" Concrete Cutter 1800 • • • • •
7-1/4" Circular Saw 2000 • • • • •
Air Compressor 2000 • • • • •
Submersible Pump 1 HP 2000 • • • • •
Concrete Vibrator 2000 • • • • •
Air Conditioner 13,500 BTU 1200 • • • • •
Air Conditioner 10,000 BTU 2500 • • • •
Air Conditioner 15,000 BTU • • • •
Premium
Series
YG2800i
YG4000D
YG5200D
YG6600D
This chart provides information on the wattage needs
of common commercial devices and tools:
INDUSTRIAL GENERATOR WORKSHEET
Running
Wattage
Requirements*
COMMERCIAL
PRODUCTS:
YG6600DE
1/4" Drill 300 300
Jigsaw 300 300
Electric Weed Trimmer 500 500
Router 1000 1000
Belt Sander 1000 1000
Disc Sander 1200 1200
Chain Saw 1200 1200
Worm Drive Saw 1560 3100
12" Concrete Cutter 1800 3600
7 1/4" Circular Saw 1500
Disc Grinder 2000 4000
Air Compressor,
2000 4000
Average
COMMERCIAL
PRODUCTS:
•
Additional
Starting
Wattage
Requirements
SUB-TOTAL:
GRAND TOTAL
Totals
*Running wattage values are for estimation only.
1-23
Yamaha Generator Theory & Diagnostics Guide
CONSUMER DECIBEL LEVEL
COMPARISONS
GENERAL ESTIMATES OF WORK-RELATED NOISES
Ambulance Siren
120
120
Hammer Drill
114
114
Airless Paint Sprayer
105
105
Tractor
96
96
Lawn Mower
90
90
EF12000DE 80 dBA
EF5200D,
EF6600DE
EF4000DE,
EF2600A
EF2600
EF2800i
EF2400iS
EF3000iSE,
EF3000iSEB
73.5 dBA
69 dBA
67 dBA
60~67 dBA
53~58 dBA
51~57 dBA
80
70
60
50
Ringing Telephone
80
Vacuum Cleaner
70
Normal Speech
60
Business Office
50
INDUSTRIAL DECIBEL LEVEL
COMPARISONS
GENERAL ESTIMATES OF WORK-RELATED NOISES
120
Ambulance Siren
119
Pneumatic Drill
Hammer Drill
114
108 Continuous Miner
Airless Paint Sprayer
105
98 Hand Drill
Tractor
96
Lawn Mower
90
Ringing Telephone
80
Vacuum Cleaner
70
Normal Speech
60
Business Office
50
YG5200D,
YG6600D,
YG6600DE
YG000D 69 dBA
YG2800i 60~69 dBA
73.5 dBA
120
114
105
96
90
80
70
60
50
EF1000iS 47~57 dBA
35
25
Soft Whisper
35
Bedroom at Night
25
35
25
Soft Whisper
35
Bedroom at Night
25
1-24
Model Name Clarification YG/EF
Yamaha generators have various model names that
represent the characteristics of the respective models as follows:
Consumer Generators
E F 6600 DE
AC Max. output B: Boost Technology
(kVA) at 60Hz D: Dual 120/240V AC output
E: Electric Starter
F: Four stroke I: Inverter Technology
DA: Air cooled diesel engine S: Soundproof Type
DL: Liquid cooled diesel engine
G: Generators*
Generator Information and Theory
E: Engine generator
Y: Yamaha*
*NOTE: The letters YG are always used together to designate Yamaha Industrial Series Generators.
Model Introduction Year
Unlike Motorsports products, Yamaha does not use
or recognize model years for generators. Instead,
Yamaha uses the term Model Introduction Year
(MIY) to help identify one model from another. The
MIY is used to identify the year that a certain unit
was either first introduced to the US Market, or
received a significant technological update. The MIY
does not necessarily coincide with the actual year of
manufacture. In certain cases it may be necessary
to explain this to a customer who is buying a new
generator from your dealership. This explanation will
create a higher level of customer satisfaction by
preventing a customer from believing that they are
buying a used/or non-current generator.
1-25
Yamaha Generator Theory & Diagnostics Guide
EXTENSION CORD GUIDELINES
A proper extension cord must always be used. If a
cord is not heavy enough for the load it must carry,
it could burn or there could be a severe reduction in
power available at the end of the cord.
The following chart shows the minimum extension
cord wire size for the amount of the expected load.
Note that the wire size increases with the length of
the cord as the anticipated load increases. Lightgauge cords can be easily damaged. Practical considerations suggest that small-size cords (20 gauge
or smaller) be avoided.
EXTENSION CORD GAUGE
*LOAD
(AMPERES)
2 22 20 18
3 22 18 16
4 20 16 16
5 18 16 14
6 18 16 14
8 16 14 12
10 16 12 12
12 16 12 10
14 14 12 10
16 14 10 10
18 14 10 8
20 12 10 8
22 12 10 8
25 12 10 8
30 10 8 6
35 10 8 6
40 8 6 4
50 6 4 2
60 4 2 2
MINIMUM GAUGE (AWG)
0 ~ 50 Feet 50 ~ 100 Feet 100 ~ 150 Feet
Resistor and Non-Resistor Spark Plugs
Resistor type spark plugs are used in all Yamaha
generators. Do not use non-resistor type spark
plugs. Refer the Owner’s Manual or Service Manual
for complete information.
Neutral Ground and Floating Ground (Open
Ground – False Ground+)
Neutral Ground (also called “neutral bond”) means
earth ground and neutral are bonded together
(wired together). This creates less chance of electrocution by providing two paths for electricity to travel
in the event of a short.
Floating Ground means that earth ground and neutral are NOT bonded together. All Yamaha Inverters
use a “floating ground” grounding method.
Devices that require a Neutral Ground (bonded neutral) will not work correctly when plugged into a floating ground generator - this is because the device
can not locate an earth ground presence.
Ground Fault Circuit Interrupter (GFCI)
A GFCI protected outlet interrupts power delivery
when a fault or short to ground is detected to prevent electrocution. It is a device that interrupts the
power flowing through a GFCI receptacle when a
proper ground is not present or if/when a short
occurs. All Yamaha Industrial series generators (YG
models) are equipped with GFCI protected outlets.
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