Yamaha EF4500iSE - Inverter Generator User manual

Generator
7XF-28199-10
EF4500iSE
OWNER’S MANUAL
PLEASE READ AND UNDERSTAND THIS MANUAL
COMPLETELY BEFORE OPERATING THE MACHINE. LIT-19626-01-46
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2008 902 – 1.0 ×1 !
7XF-28199-10_hyoshi 08.1.25 9:33 AM Page 1

7XF-28199-10_hyoshi 08.1.25 9:33 AM Page 2

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.
EF4500iSE
OWNER’S MANUAL
© 2008 by Yamaha Motor Corporation, U.S.A.
1st Edition, February 2008
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-19626-01-46
AE00022
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Particularly important information is distin-
guished in this manual by the following
notations.
-
The Safety Alert Symbol means ATTEN-
TION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
w
Failure to follow WARNING instructions
could result in severe injury or death to
the engine operator, a bystander or a per-
son inspecting or repairing the engine.
cC
A CAUTION indicates special precautions
that must be taken to avoid damage to the
engine.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
AE00032
w
PLEASE READ AND UNDERSTAND
THIS MANUAL COMPLETELY BEFORE
OPERATING THE MACHINE.
NOTE:
9Yamaha 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 manu-
al, please consult a Yamaha dealer.
9This 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.
IMPOTANT MANUAL INFORMATION
7XF-28199-10_a 08.1.31 9:19 Page A-2

AE00041
CONTENTS
SAFETY INFORMATION ........................1
EXHAUST FUMES ARE
POISONOUS........................................1
FUEL IS HIGHLY FLAMMABLE AND
POISONOUS........................................1
ENGINE AND MUFFLER MAY BE
HOT ......................................................1
ELECTRIC SHOCK PREVENTION......2
CONNECTION NOTES ........................3
CONNECTION .....................................3
EXTENSION CORD NOTES................3
LOCATION OF IMPORTANT
LABELS...................................................4
DESCRIPTION ........................................6
Control Panel........................................6
CONTROL FUNCTION............................7
Engine switch .......................................7
Oil warning light (red) ...........................7
AC protector .........................................8
Hour meter............................................8
Power meter .........................................8
AC pilot light (green).............................8
Overload indicator light.........................9
Fuel tank cap ........................................9
Fuel cock knob ...................................10
Ground (Earth) terminal......................10
PREPARATION.....................................11
Fuel.....................................................11
Engine oil............................................12
Battery preparation .............................13
PRE-OPERATION CHECK ...................15
Pre-operation check ...........................15
OPERATION..........................................16
Starting the engine .............................16
Stopping the engine............................18
Connection .........................................19
Application range................................20
PERIODIC MAINTENANCE ..................21
Maintenance chart ..............................21
Spark plug inspection .........................23
Carburetor adjustment........................24
Engine oil replacement .......................24
Air filter ...............................................25
Muffler screen and spark arrester.......27
Fuel tank filter .....................................29
Battery ................................................30
Recommended battery .......................30
Fuse replacement...............................31
STORAGE .............................................32
Drain the fuel ......................................32
Engine ................................................32
Battery ................................................33
Engine won’t start ...............................34
TROUBLESHOOTING ..........................35
Generator won’t produce power .........35
SPECIFICATIONS.................................37
Dimensions.........................................37
Engine ................................................37
Generator ...........................................37
Battery ................................................37
CONSUMER INFORMATION................38
Identification number records .............38
Machine identification .........................38
LIMITED WARRANTY (EF- AND
EDL-SERIES) ........................................39
EXHAUST EMISSION CONTROL
SYSTEM AND COMPONENTS .........41
WIRING DIAGRAM ...............................43
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– 1 –
741-7XFa
741-7XFb
741-7XFc
741-7XFd
741-7XFe
741-7XFf
AE00071
SAFETY INFORMATION
AE00072
EXHAUST FUMES ARE POISONOUS
9Never 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
9Always turn off the engine when refuelling.
9Never refuel while smoking or in the vicinity of an
open flame.
9Take care not to spill any fuel on the engine or
muffler when refuelling.
9If 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.
9When operating or transporting the machine, be
sure it is kept upright. If it tilts, fuel may leak from
the carburetor or fuel tank.
AE00843
ENGINE AND MUFFLER MAY BE HOT
9Place the machine in a place where pedestrians
or children are not likely to touch the machine.
9Avoid placing any flammable materials near the
exhaust outlet during operation.
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–2 –
741-7XFg
a
741-7XFh
1
794-7XFa
741-7XFi
741-7XFj
9Keep the machine at least 1 m (3 ft) from buildings
or other equipment, or the engine may overheat.
a1 m (3 ft)
9Avoid operating the engine with a dust cover.
9Be sure to carry the generator only by its carrying
handle(s).
1Carrying handle(s) (shaded)
AE00083
ELECTRIC SHOCK PREVENTION
9Never operate the engine in rain or snow.
9Never touch the machine with wet hands or elec-
trical shock will occur.
9Connect the ground lead of the machine to the
ground terminal and connect the end to the
ground electrode buried in the ground.
1Ground (Earth) terminal
1
763-7XFa
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–3 –
1
2
1
2
741-7XFk
AE00088
CONNECTION NOTES
9Avoid connecting the generator to commercial
power outlet.
9Avoid connecting the generator in parallel with any
other generator.
1Correct
2Incorrect
AE00091
CONNECTION
w
Before the generator can be connected to a build-
ing’s electrical system, a licensed electrician must
install an isolation (transfer) switch in the build-
ing’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 build-
ing electrical system damage can occur when nor-
mal operating power returns if unit is used without
an isolation switch.
AE00086
EXTENSION CORD NOTES
Extension cords should be protected by a tough flexi-
ble rubber sheath (IEC 245) or the equivalent to with-
stand mechanical stresses.
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–4 –
AE00062
LOCATION OF IMPORTANT LABELS
Please read the following labels carefully before oper-
ating this machine.
NOTE:
Maintain or replace safety and instruction labels, as
necessary.
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.
3
5
1642
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–5 –
35
2
6
WARNING
READ THE OWNER‘S MANUAL AND ALL LABELS BEFORE OPERATING.
qqAVERTISSEMENT
8
ONLY OPERATE IN WELL-VENTILATED AREAS.
EXHAUST GAS CONTAINS POISONOUS CARBON MONOXIDE.
CHECK FOR SPILLED FUEL OR FUEL LEAKS.
STOP ENGINE BEFORE REFUELING.
DO NOT OPERATE NEAR FLAMMABLE MATERIALS.
ELECTROCUTION CAN OCCUR IF GENERATOR IS USED IN RAIN,
SNOW, OR NEAR WATER. KEEP THIS UNIT DRY AT ALL TIMES.
8
8
8
8
8
MACHINE AU SEC EN TOUTES CIRCONSTANCES.
8
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.
7CF-24162-10
Important Emissions Information The air index of this engine is 3
(California only)
MOST CLEAN LEAST CLEAN
0246810
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: *YMXS.3572EA DISPLACEMENT: 357cc
EVAP F: CMYMX23A 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
(250 HOURS)
INTERMEDIATE
(500 HOURS)
EXTENDED
(1000 HOURS)
X
HOT EXHAUST
7WL-28176-10
4
qCAUTION
Use the specified spark plug only.
Specified plug:BPR4ES(NGK)
OIL
zzzzzz
AC output zzHz
Rated zzzzVA
Phase Single
Fuel
Gasoline
YAMAHA MOTOR POWERED PRODUCTS CO.,LTD.
MADE IN JAPAN
zzzV
7XF-24164-10
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–6 –
DESCRIPTION
AE00102
1Carrying handles (shaded)
2Fuel tank cap
3Fuel gauge
4Muffler
5Caster lock lever
6Oil filler cap
7Oil drain plug
8Battery
AE00103
Control panel
1Hour meter
2Power meter
3AC protector
4AC receptacle
5Engine switch
6Fuel cock knob
7Ground (Earth) terminal
8Overload indicator light
9AC pilot light
0Oil warning light
793-7XF
7
6
5
134
9 80
2
3 121
793-7XFa
7 6 58
4
793-7XFb
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763-119
q
we
–7 –
700-7XF
AE00111
Oil warning light (red)
When the oil level falls below the lower level, the oil
warning light comes on and then the engine stops
automatically. Unless you refill with oil, the engine will
not start again.
NOTE:
If the engine stalls or does not start, turn the engine
switch to “START”position. If the oil warning light
comes on, the engine oil is insufficient. Add oil and
restart.
AE00101
CONTROL FUNCTION
AE00121
Engine switch
The engine switch controls the ignition system.
17“ON”
Ignition circuit is switched on.
The engine can be started.
25“STOP”
Ignition circuit is switched off.
The engine will not run.
36“START”
Starting circuit is switched on.
The starter motor starts and the engine can be started.
After starting the engine, take your hand off the switch
immediately.
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–8 –
793-7XFe
1
2
AE00134
AC protector
The AC protector 1trips when total amount of the two
receptable 2loads exceeds 20A.
Press the switch to reset the AC protector.
1I“Set”
23“Reset”
763-238a
1
2
1
763-7XFf
1
763-7XFg
1
763-7XFc
Hour meter
The hour meter 1shows the total number of hours
the generator has been run.
Power meter
The power meter 1shows the amount of electric cur-
rent used by a barmeter.
The generator output is normal when the segments of
the barmeter appear.
NOTE:
When 10 segments appear, the generator has almost
reached its rated output.
AC pilot light (green)
The AC pilot light 1comes on when the engine starts
and produces power.
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–9 –
AE01087
Overload indicator light
The overload indicator light 1comes on when an
overload of a connected electrical device is detected,
the inverter control unit overheats, or the AC output
voltage rises. Then, the AC protector will trip, stopping
power generation in order to protect the generator and
any connected electric devices. The AC pilot light
(green) will go off and the overload indicator light (red)
will stay on, but the engine will not stop running.
When the overload indicator light comes on and power
generation stops, proceed as follows:
1. Turn off any connected electric devices and stop
the engine.
2. Reduce the total wattage of connected electric
devices within the rated output.
3. Check for blockages in the cooling air inlet and
around the control unit. If any blockages are
found, remove.
4. After checking, restart the engine.
NOTE:
The overload indicator light may come on for a few
seconds at first when using electric devices that
require a large starting current, such as a compressor
or a submergible pump. However, this is not a mal-
function.
1
763-7XFd
707-7XFb
Fuel tank cap
Remove the fuel tank cap by turning it counterclock-
wise.
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–10 –
763-7XFb
705-073c
ON
OFF
1
763-7XFa
Fuel cock knob
The fuel cock supplies fuel from the fuel tank to the
carburetor.
The fuel cock has two positions.
ON
With the knob in this position, fuel flows to the carbure-
tor. Normal using is done with the knob in this position.
OFF
With the knob in this position, fuel will not flow. Always
turn the knob to this position when the engine is not
running.
Ground (Earth) terminal
It is a terminal which connects the earth line for pre-
vention of electric shock.
When the electric device is earthed, always the gener-
ator must be earthed.
1Ground (Earth) terminal
1
2
788-7XFh
Caster lock lever
The caster lock lever stops moving the generator.
1“Release”
2“Lock”
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–11 –
741-7XFl
1
2
707-7XF
707-7XFc
3 4
707-7XFa
PREPARATION
AE00856
Fuel
w
9Fuel is highly flammable and poisonous.
Check “SAFETY INFORMATION”(See page 1)
carefully before filling.
9Do not overfill the fuel tank, otherwise it may
overflow when the fuel warms up and
expands.
9After fill the fuel, make sure the fuel tank cap is
tightened securely.
cC
9Immediately wipe off spilled fuel with a clean,
dry, soft cloth, since fuel may deteriorate
painted surfaces or plastic parts.
9Use only unleaded gasoline. The use of leaded
gasoline will cause severe damage to internal
engine parts.
Make sure there is sufficient fuel in the tank.
When refueling, be sure to fill the tank to the bottom
edge of the fuel filter 4.
1Fuel level gauge
2Red line
3Fuel level
Your Yamaha engine has been designed to use regu-
lar unleaded gasoline with a pump octane number ((R
+ M)/2) of 86 or higher, or research octane number of
91 or higher.
Recommended fuel:
Unleaded gasoline
Fuel tank capacity:
Total:
17.0 L (3.17 US gal, 2.64 Imp gal)
“F”Full
Red line 2Empty
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–12 –– 12 –
3
700-7XFa
700-103c
r
0°C
åYAMALUBE 4 (10W-30 or 10W-40)
∂SAE 10W çSAE #20 ∫SAE #30
32°F
25°C
80°F
700-006
AE00222
Engine oil
cC
The generator has been shipped without engine
oil. Do not start the engine before filling with the
sufficient engine oil.
1. Place the generator on a level surface.
2. Remove the bolts 1, and then pull outward on the
areas of rear cover 2shown.
3. Remove the oil filler cap 3.
4. Fill the specified amount of the recommended
engine oil, and then install and tighten the oil filler
cap.
4Upper level
Recommended engine oil:
åYAMALUBE 4 (10W-30 or 10W-40),
SAE 10W-30 or 10W-40
∫SAE #30
çSAE #20
∂SAE 10W
Recommended engine oil grade:
API Service SE type or higher
Engine oil quantity:
1.3 L (1.14 US qt, 1.37 lmp qt)
1
2
788-7XFb
5. Install the rear cover and tighten the bolts.
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–13 –
AE01083
Battery preparation
(See page 30)
w
Battery electrolyte is poisonous and dangerous,
causing severe burns, etc. It contains sulfuric (sul-
phuric) acid. Avoid contact with skin, EYES or
clothing.
Antidote:
EXTERNAL-Flush with water.
INTERNAL-Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg or veg-
etable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get
prompt medical attention. Batteries produce explo-
sive gases. Keep sparks, flame, cigarettes, etc.
away. Ventilate when charging or using in closed
space. Always cover eyes when working near bat-
teries. KEEP OUT OF REACH OF CHILDREN.
762-012
1. Remove the bolts 1, and then pull outward on the
areas of rear cover 2shown.
2. Remove the wing nuts 3and battery plate 4.
3. Remove the battery 5.
4. Fill the battery with the electrolyte.
Refer to the instruction sheet included with the
electrolyte for filling instructions.
5. Turn the engine switch to the “STOP”position to
prevent accidental short circuiting.
6. Connect the positive lead (red) 6to the positive
(+) battery terminal 7.
7. Install the battery 5onto the tray.
8. Install the battery plate 4and tighten the wing
nuts 3.
1
2
788-7XFb
3
5
4
762-7XFa
6
7
762-7XFc
7XF-28199-10_a 08.1.31 9:19 Page 13

–14 –
9. Connect the negative lead (black) 8to the nega-
tive (-) battery terminal 9.
10. Install the rear cover and tighten the bolts.
8
9
762-7XFd
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–15 –
AE00845
PRE-OPERATION CHECK
w
If any item in the Pre-operation check is not work-
ing properly, have it inspected and repaired before
operating the generator.
The condition of a generator is the owner's responsibil-
ity. Vital components can start to deteriorate quickly
and unexpectedly, even if the generator unused.
NOTE:
Pre-operation checks should be made each time the
generator is used.
Pre-operation check
Fuel (See page 11)
9Check fuel level in fuel tank.
9Refuel if necessary.
Fuel line
9Check fuel hose for crack or damage.
9Replace if necessary.
Engine oil (See page 12)
9Check oil level in engine.
9If necessary, add recommended oil to specified
level.
9Check generator for oil leakage.
The point where abnormality was recognized by
use.
9Check operation.
9If necessary, consult a Yamaha dealer.
7XF-28199-10_a 08.1.31 9:19 Page 15