Yamaha EF7200DE, EF7200D User manual

Generator
LIT-19626-02-76
7P6-F8199-13
PRINTED IN CHINA
2019.12×1 !
(E)
EF7200DE
EF7200D
OWNER’S MANUAL
Read this manual carefully before operating this machine.
7P6-F8199-13_hyoshi.indd 1-2 2019/12/11 9:57:58

Read this manual carefully before operating this machine. This manual should
stay with this machine if it is sold.

7P6-F8199-13_hyoshi.indd 3-4 2019/12/11 9:57:59

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.
EF7200DE/EF7200D
OWNER’S MANUAL
© 2019 by Yamaha Motor Corporation, U.S.A.
1st Edition, December 2019
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in China
P/N LIT-19626-02-76
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Particularly important information is distin-
guished in this manual by the following
notations.
This is the safety alert symbol. It is
used to alert you to potential personal
injury hazards. Obey all safety messag-
es that follow this symbol to avoid pos-
sible injury or death.
WARNING
A WARNING indicates a hazardous sit-
uation which, if not avoided, could
result in death or serious injury.
NOTICE
A NOTICE indicates special precau-
tions that must be taken to avoid dam-
age to the machine or other property.
TIP
A TIP provides key information to make
procedures easier or clearer.
WARNING
PLEASE READ AND UNDERSTAND
THIS MANUAL COMPLETELY BEFORE
OPERATING THE MACHINE.
TIP
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 machine and this manual. If
there is any question concerning this
manual, please consult a Yamaha
dealer.
9This manual should be considered a
permanent part of this machine and
should remain with this machine
when resold.
* Product and specifications are subject to
change without notice.
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SAFETY INFORMATION ...................... 1
Exhaust fumes are poisonous............ 2
Fuel is highly flammable and
poisonous........................................... 2
Engine and muffler may be hot .......... 2
Electric shock prevention ................... 3
Connection notes ............................... 4
Connection......................................... 4
Extension cord notes.......................... 4
LOCATION OF IMPORTANT
LABELS ................................................ 5
DESCRIPTION...................................... 6
Control panel (For EF7200DE) .......... 7
Control panel (For EF7200D)............. 7
CONTROL FUNCTION ......................... 8
Engine switch ..................................... 8
Oil warning light (Red)........................ 8
AC switch (N.F.B.) .............................. 9
Fuel tank cap...................................... 9
Fuel cock lever ................................... 9
Ground (earth) terminal.................... 10
Economy control switch.................... 10
Choke lever ...................................... 10
Recoil starter.................................... 11
Starter switch (For EF7200DE)........ 11
Voltage adjuster ............................... 11
G.F.C.I. receptacle............................ 12
PREPARATION ................................... 13
Two wheel kit installation.................. 13
Fuel .................................................. 18
Engine oil ......................................... 19
Battery (For EF7200DE) .................. 20
Ground (earth) terminal.................... 21
PRE-OPERATION CHECK ................. 22
Pre-operation check ......................... 22
OPERATION ....................................... 23
Starting the engine........................... 23
Stopping the engine ......................... 25
Connection....................................... 26
Application range ............................. 29
High altitude operation .................... 30
PERIODIC MAINTENANCE................ 31
Maintenance chart ........................... 31
Carburetor adjustment ..................... 33
Spark plug inspection....................... 33
Engine oil replacement..................... 34
Muffler screen and spark arrester .... 36
Air filter............................................. 38
Fuel cock.......................................... 39
Fuel tank filter................................... 40
Battery (For EF7200DE) .................. 41
Recommended battery
(For EF7200DE)............................... 41
Fuse replacement
(For EF7200DE)............................... 42
G.F.C.I. receptacle test ..................... 43
STORAGE ........................................... 44
Drain the fuel.................................... 44
Engine.............................................. 45
Battery (For EF7200DE) .................. 46
TROUBLESHOOTING ........................ 47
SPECIFICATIONS............................... 52
Dimensions ...................................... 52
Engine.............................................. 52
Generator ......................................... 52
CONSUMER INFORMATION.............. 53
Identification number records........... 53
Machine identification....................... 53
EXHAUST EMISSION CONTROL
SYSTEM AND COMPONENTS .......... 54
WIRING DIAGRAM ............................. 55
EF7200DE........................................ 55
EF7200D.......................................... 56
YAMAHA EXTENDED SERVICE
(Y.E.S.) ................................................ 57
CONTENTS
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– 1 –
SAFETY INFORMATION
9This generator is not designed for on-board use.
Do not use it while installed on the vehicle.
9Do not modify the generator or use it with its parts
removed.
9Do not allow children to operate the generator.
9Be sure to carry the generator only by its carrying
handle(s).
1Carrying handle(s) (shaded)
9Do not place any obstacles on the generator.
1
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– 2 –
741-003
741-005
741-004
741- 006
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.
9Do not leave the generator inside the vehicle or in
the trunk.
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 generator, be
sure it is kept upright. If it tilts, fuel may leak from
the carburetor or fuel tank.
Engine and muffler may be hot
9Place the generator in a place where pedestrians
or children are not likely to touch the generator.
741-002
Exhaust fumes are poisonous
9Using a generator indoors CAN KILL YOU IN
MINUTES. Generator exhaust contains carbon
monoxide. This is a poison you cannot see or
smell.
9NEVER use inside a home or garage, EVEN IF
doors and windows are open.
9Only use OUTSIDE and far away from windows,
doors, and vents.
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– 3 –
741-007
9Avoid placing any flammable materials near the
exhaust outlet during operation.
741-008a
9In order to prevent overheating, ensure adequate
airflow by keeping the machine at least 1 m (3 ft)
from objects or other equipment.
7CC-001
741-010
741-011
9Do not operate the engine with a dust cover or
other objects covering it.
9When covering the generator, be sure to do so
only after the engine and muffler have completely
cooled down.
Electric shock prevention
9Never operate the engine in rain or snow.
9Never touch the generator with wet hands or elec-
trical shock will occur.
9Connect the ground (earth) terminal to a ground
source. In order to prevent electrical shock, the
generator must be grounded when using a
grounded electrical device.
1Ground (earth) terminal
1
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– 4 –
741-040a
1
2
1
2
Connection notes
9Avoid connecting the generator to commercial
power outlet.
9Avoid connecting the generator in parallel with any
other generator.
1Correct
2Incorrect
Connection
WARNING
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.
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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– 5 –
LOCATION OF IMPORTANT LABELS
Please read the following labels carefully before oper-
ating this generator.
TIP
Maintain or replace safety and instruction labels, as
necessary.
2
4
OIL
HOT EXHAUST
WARNING
Read the owner’s manual and all labels before operating.
Only operate in well-ventilated areas.
Exhaust gas contains poisonous carbon monoxide.
Check for spilled fuel or fuel leaks.
Stop engine before refueling.
Do not operate near flammable materials.
Electrocution can occur if generator is used in rain,
snow, or near water. Keep this unit dry at all times.
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.
When operating the generator:
Never place a partition or other barrier around the generator.
Do not cover the generator with a box.
Do not place any objects on the generator.
7PB-F4162-10
5
DISPLACEMENT :
3
6
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. 7C2-F4877-00
1
2
3
4
5
6
1
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– 6 –
DESCRIPTION
1Carrying handles (shaded)
2Fuel tank cap
3Fuel level gauge
4Fuel tank
5Voltage adjuster
6Ground (earth) terminal
7Battery (For EF7200DE)
8Oil filler cap
9Oil drain bolt
0Spark plug
qFuel cock
wRecoil starter handle
eAir filter case cover
rChoke lever
tMuffler
EF7200DE
2
8
5
6
1 13 4
9
7
2
5
6
113 4
8
9
EF7200D
0 q
w
re
t
0 q
w
re
t
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– 7 –
Control panel
(For EF7200DE)
1Oil warning light (Red)
2Economy control
switch
3Engine switch
4Voltage/hour meter
5Starter switch
6G.F.C.I. receptacle
7AC receptacle
8AC switch (N.F.B.)
EF7200DE
8
3 4 521 6 7 8
000-000
Control panel
(For EF7200D)
1Oil warning light (Red)
2Economy control
switch
3Engine switch
4Voltage/hour meter
5G.F.C.I. receptacle
6AC receptacle
7AC switch (N.F.B.)
EF7200D
7
3 421 5 6 7
000-000
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– 8 –
1
2
CONTROL FUNCTION
Engine switch
The engine switch controls the ignition system.
1 “7” (ON)
Ignition circuit is switched on.
The engine can be started.
2 “5” (STOP)
Ignition circuit is switched off.
The engine will not run.
700-027c
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.
TIP
If the engine stalls or does not start, turn the engine
switch to “7” (ON) and then push the starter switch
(for EF7200DE) or pull the recoil starter. If the oil warn-
ing light flickers for a few seconds, the engine oil is
insufficient. Add oil and restart.
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– 9 –
AC switch (N.F.B.)
The AC switch (Non-Fuse Breaker) turns off automati-
cally when the load exceeds the generator rated out-
put.
1“I” (ON)
2“3” (OFF)
1
2
1
2
000-000
2
1
000-000
A
1
1
000-000
B
åSupplies AC 120 V
∫Supplies AC 120 V and 240 V
NOTICE
Reduce the load to the specified generator rated
output if the AC switch (N.F.B.) turns off. If it turns
off again, consult a Yamaha dealer.
Fuel tank cap
Remove the fuel tank cap by turning it counterclock-
wise.
7DF-106
1
22
Fuel cock lever
The fuel cock supplies fuel from the fuel tank to the
carburetor.
The fuel cock has two positions.
1ON
With the lever in this position, fuel flows to the carbure-
tor. Normal using is done with the lever in this position.
2OFF
With the lever in this position, fuel will not flow. Always
turn the lever to this position when the engine is not
running.
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– 10 –
1
Ground (earth) terminal
Ground (earth) terminal connects the earth line for
prevention of electric shock.
When the electric device is earthed, always the gener-
ator must be earthed.
1Ground (earth) terminal
1
Choke lever
Starting a cold engine requires a richer air-fuel mix-
ture, which is supplied by the choke lever.
1Choke lever
1
2
240V
120V
120V
GR
WX
G
Y
Economy control switch
1“I” (ON)
When the economy control switch is turned to “I” (ON),
the economy control unit controls the engine speed
according to the connected load. The results are better
fuel consumption and less noise.
2“3” (OFF)
When the economy control switch is turned to “3”
(OFF), the engine runs at the rated r/min (3600 r/min)
regardless of whether there is a load connected or not.
TIP
9The economy control switch must be turned to “3”
(OFF) when using electric devices that require a
large starting current, such as a compressor or a
submersible pump.
9The economy control switch must be turned to “3”
(OFF) to increase engine speed to rated r/min
when:
- using a load of 0.8 A or less.
- supplying AC 120 V only from W with X.
7P6-F8199-13.indd 10 2019/12/11 9:57:20

– 11 –
Starter switch (For EF7200DE)
The starter switch controls the following item.
Push:
Starting circuit is switched on.
Release:
Starting circuit is switched off.
NOTICE
Take your hand off the switch immediately after the
engine starts.
Recoil starter
The recoil starter is used to start the engine.
Pull the recoil starter slowly until it is engaged, then
pull it briskly.
1Recoil starter handle
NOTICE
9Pull the recoil starter handle straight.
9Return the recoil starter handle slowly.
9Do not touch the recoil starter handle while the
generator is operating.
000-000
1
000-000
Voltage adjuster
The voltage adjuster is equipped for adjusting output
voltage to rated voltage.
TIP
Turn the voltage adjuster clockwise or counterclock-
wise to increase or decrease output voltage.
7P6-F8199-13.indd 11 2019/12/11 9:57:20

– 12 –
3
763-060
G.F.C.I. receptacle
WARNING
TO REDUCE THE CHANCE OF ELECTRICAL
SHOCK:
9Do not attempt to operate electric devices if
the ground fault circuit interrupter reset button
pops out repeatedly during use.
9Test the ground fault circuit interrupter during
the pre-operation checks according to the
maintenance instructions on page 43.
9Remember that only receptacle labeled “GFCI”
have ground fault circuit interrupter protection.
The G.F.C.I. (Ground Fault Circuit Interrupter) shuts off
power to the protected receptacles if a ground fault
(electrical leak) is detected.
If the reset button pops out, the electric devices con-
nected into the receptacle may be faulty. If this hap-
pens, check the electric devices carefully. If the electric
devices appears to be in good condition, press the
reset button firmly until a click is heard. This will
restore power. If the reset button pops out again, dis-
connect all the electric devices immediately. Have the
electric devices inspected and repaired by a qualified
repairperson before attempting to use them again.
1G.F.C.I. (Ground Fault Circuit Interrupter)
2Reset button
3Pop out
000-000
1
2
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– 13 –
PREPARATION
Two wheel kit installation
1. Fasten the engine hanger to the carrier frame with
the bolts.
TIP
Match the punch marks as shown in the illustration.
1Bolt (8 × 16 mm Flange bolt)
2Engine hanger
3Carrier frame
Tightening torque:
16 N·m (1.6 kgf·m, 12 lb·ft)
2. Install the damper and plate into the stopper, and
tightly fasten it to carrier frame with the bolt.
4Damper
5Plate
6Stopper
7Bolt (6 × 16 mm Flange bolt)
Tightening torque:
7 N·m (0.7 kgf·m, 5.2 lb·ft)
000-000
1
2
3
1
000-000
000-000
4
5
6
000-000
7
7P6-F8199-13.indd 13 2019/12/11 9:57:21

– 14 –
4. Place the carrier frame on the generator body so
that the lock lever is positioned on the left side of
the control panel. Fasten the plate to the carrier
frame with the bolts.
TIP
Place the carrier frame 10 cm (3.94 in) from the end of
generator body.
a10 cm (3.94 in)
Tightening torque:
16 N·m (1.6 kgf·m, 12 lb·ft)
rBolt (8 × 45 mm Flange bolt)
tPlate
3. Insert the bolt into the carrier frame, and then put
the washer, collar, and lock lever in this order, and
tighten the nut.
TIP
9Make sure that the collar is placed into the washer.
9Lock lever pin should be above stopper.
8Nut (8 mm Flange nut [Self-locking nut])
9Lock lever
0Collar
qWasher (Plastic)
wBolt (8 × 60 mm Flange bolt)
eStopper
Tightening torque:
16 N·m (1.6 kgf·m, 12 lb·ft)
a
000-000
r
t
t
000-000
r
t
000-000
89
0q
w
000-000
9e
7P6-F8199-13.indd 14 2019/12/11 9:57:21

– 15 –
8. Place the handle on the carrier frame, and then
fasten with the bolts.
TIP
Lock the handle into position with the lock lever.
pBolt (8 × 16 mm Flange bolt)
aHandle
Tightening torque:
16 N·m (1.6 kgf·m, 12 lb·ft)
9. Lift the engine 20 cm (7.87 in) off the ground using
a winch or other suitable lifting device.
000-000
p
a
p
000-000
5. Install the sleeve on the generator frame.
TIP
Refer to the illustration to be sure that the sleeve is
installed properly.
ySleeve
uGenerator frame
6. Install the bracket handle to the sleeve.
iBracket handle
7. Install the locating damper on the sleeve.
oLocating damper
000-000
yu
000-000
y
i
000-000
y
o
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