EF1600, EF2600, YG2600 Owner's Manual - Yamaha Motorsports

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Generator
LIT-19626-01-14 7NJ-28199-12PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
03 908 – 0.4 × 1 !
EF1600
EF2600
YG2600
OWNER’S MANUAL
7NJ-9-12 Hyoshi 10/27/03 9:03 AM Page 1
7NJ-9-12 Hyoshi 10/27/03 9:03 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.
PRI-I.D. NUMBER 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
© 2003 by Yamaha Motor Corporation, U.S.A.
1st Edition, August 2003
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-19626-01-14
790-025a
MODEL
PRI-I.D.
CODE SERIAL No.
790-062
AE00022
7NJ-9-12A 10/27/03 10:20 AM Page a
851-005
AE00032
w 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!
w Failure to follow WARNING instructions
could result in severe injury or death to
the engine operator, a bystander, or a
person 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.
NOTE:
9 Yamaha continually seeks advancements 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.
7NJ-9-12A 10/27/03 10:20 AM Page b
AE00041
CONTENTS
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
7NJ-9-12A 10/27/03 10:20 AM Page c
– 1 –
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 specified 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 WAR-
RANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE WHICH EXCEED
THE OBLIGATIONS AND TIME LIMITS STATED IN
THIS WARRANTY ARE HEREBY DISCLAIMED BY
YAMAHA MOTOR CORPORATION, U.S.A. AND
EXCLUDED FROM THIS WARRANTY.
SOME STATES DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, SO
THE ABOVE LIMITATION MAY NOT APPLY TO
YOU. ALSO EXCLUDED FROM THIS WARRANTY
ARE ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES INCLUDING LOSS OF USE. SOME
STATES DO NOT ALLOW THE EXCLUSION OR
LIMITATION OF INCIDENTAL OR CONSEQUEN-
TIAL 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
AE01119
YAMAHA MOTOR CORPORATION U.S.A.
EF- AND EDL-SERIES GENERATOR LIMITED WARRANTY
7NJ-9-12A 10/27/03 10:20 AM Page 1
– 2 –
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.
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 industrial 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 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.
YAMAHA MOTOR CORPORATION, U.S.A. MAKES
NO OTHER WARRANTY OF ANY KIND,
EXPRESSED OR IMPLIED. ALL IMPLIED WAR-
RANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE WHICH EXCEED
THE OBLIGATIONS AND TIME LIMITS STATED IN
THIS WARRANTY ARE HEREBY DISCLAIMED BY
YAMAHA MOTOR CORPORATION, U.S.A. AND
EXCLUDED FROM THIS WARRANTY.
SOME STATES DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, SO
THE ABOVE LIMITATION MAY NOT APPLY TO
YOU. ALSO EXCLUDED FROM THIS WARRANTY
ARE ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES INCLUDING LOSS OF USE. SOME
STATES DO NOT ALLOW THE EXCLUSION OR
LIMITATION OF INCIDENTAL OR CONSEQUEN-
TIAL 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
YAMAHA MOTOR CORPORATION U.S.A.
EC- AND YG-SERIES INDUSTRIAL GENERATOR LIMITED WARRANTY
7NJ-9-12A 10/27/03 10:20 AM Page 2
– 3 –
Q. What costs are my responsibility during the
warranty period?
A. The customer’s responsibility includes all
costs of normal maintenance service, nonwarranty 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 another part to fail; and so on. If you have any
specific questions on operation or maintenance, please contact your dealer for advice.
Q. Does the warranty cover incidental costs such
as transportation due to a failure?
A. No. The warranty is limited to repair of the
machine itself.
Q. May I perform any or all of the recommended
maintenance shown in the 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 owners?
A. Yes. The remainder of the existing warranty
can be transfered upon request.
The unit has to be inspected and reregistered
by an authorized Yamaha generator dealer for
the policy to remain effective.
CUSTOMER SERVICE
If your machine requires warranty service, you
must take it to any authorized Yamaha generator
dealer within the continental United States. Be
sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding
warranty, first contact the owner of the dealership.
Since all warranty matters are handled at the dealer level, this person is in the best position to help
you. If you are still not satisfied and require additional 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.
WARRANTY QUESTIONS AND ANSWERS
7NJ-9-12A 10/27/03 10:20 AM Page 3
– 4 –
AE00062
LOCATION OF IMPORTANT LABELS
Please read the following labels carefully before operating this machine.
NOTE:
Maintain or replace safety and instruction labels, as
necessary.
WARNING
READ THE OWNER‘S MANUAL AND ALL LABELS BEFORE OPERATING.
q qAVERTISSEMENT
8
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
8
MACHINE AU SEC EN TOUTES CIRCONSTANCES.
7NJ-24162-10
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
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
wr 792-003
HOT EXHAUST
1
3
0 2 4 6 8 1 0
ENGINE AIR INDEX ( C a l i f o r n i a o n l y )
LEAST CLEANMOST C L E A N
N O T E : T H E L O W E R T H E A I R I N D E X , T H E L E S S T H E P O L L U T I O N
F O R T H E F O L L O W I N G U S E :
T H I S E N G I N E I S C E R T I F I E D T O B E E M I S S I O N C O M P L I A N T
MODERATE INTERMEDIATE EXTENDED
CHECK OWNERS M A N U A L F O R F U R T H E R D E T A I L S
T H I S L A B E L T O B E R E M O V E D B Y T H E U L T I M A T E P U R C H A S E R O N L Y !
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
zzzJ IN:
TYPE
z.zz~z.zz EX: z.zz~z.zz
zzzz~zzzz AT NO LOAD
SESAE 10W-30
EMISSIONS COMPLIANCE PERIOD:CATEGORY A (EPA)
4
2
5
7NJ-9-12A 10/27/03 10:20 AM Page 4
– 5 –
741-002
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.
741-003
741-005
741-004
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- 006
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.
741-007
9 Avoid placing any flammable materials near the
exhaust outlet during operation.
7NJ-9-12A 10/27/03 10:20 AM Page 5
– 6 –
741-008a
a 9 Keep the machine at least 1 m (3 ft) from buildings
or other equipment, or the engine may overheat.
a 1 m (3 ft)
741-009
9 Avoid operating the engine with a dust cover.
q 741-067
9 Be sure to carry the generator only by its carrying
handle(s).
1 Carrying handle(s) (shaded)
741-010
AE00083
ELECTRIC SHOCK PREVENTION
9 Never operate the engine in rain or snow.
741-011
9 Never touch the machine with wet hands or electrical shock will occur.
q 741-012b
9 Be sure to ground (earth) the generator.
NOTE:
Use ground (earth) lead of sufficient current capacity.
1 Lead diameter
7NJ-9-12A 10/27/03 10:20 AM Page 6
– 7 –
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
w 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.
741-040a
q w q w 


7NJ-9-12A 10/27/03 10:20 AM Page 7
– 8 –
EF1600/EF2600
YG2600
q w!3 !3!2
i o!0 793-015
q w!3 !3!2
i o!0 793-016
t!3 !3
e u r !1
y 793-017
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)
7NJ-9-12A 10/27/03 10:20 AM Page 8
– 9 –
AE00104
CONTROL BOX
1 Engine switch
2 Oil warning light
3 Pilot light (YG2600)
4 Voltage meter
(EF1600/EF2600)
5 AC switch (N.F.B.)
6 AC receptacle
7 G.F.C.I. receptacle
EF1600
EF2600
YG2600
w r t 793-018
q y w r t 793-019
q y w e t 793-020
q yu 7NJ-9-12A 10/27/03 10:20 AM Page 9
– 10 –
700-027c
w 763-086c
OFF
ON
763-084f
q w q 763-095
OFF
ON
AE00111
OIL WARNING SYSTEM
When the oil level falls below the lower level, 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 "ON" position and then pull the recoil starter.
If the oil warning light flickers for a few seconds, the
engine oil is insufficient. Add oil and restart.
AE00122
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.
AE00131
AC SWITCH (N.F.B.)
The AC switch (Non-Fuse Breaker) turns off automatically when the load exceeds the generator rated output.
1 I “ON”
2 3 “OFF”
cC Reduce the load to the specified generator rated
output if the AC switch (N.F.B.) turns off. If it turns
off again, consult your Yamaha dealer.
7NJ-9-12A 10/27/03 10:20 AM Page 10
– 11 –
w 763-083
763-060
AE00848
G.F.C.I. RECEPTACLE
(for YG2600)
The G.F.C.I. (Ground Fault Circuit Interrupter) 1 shuts
off power to the protected receptacles if a ground fault
(electrical leak) is detected.
If the reset button 2 pops out 3, the equipment
plugged into the receptacle may be faulty. If this happens, check the equipment carefully. If the equipment
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, unplug the equipment
immediately. Have the equipment inspected and
repaired by a qualified repairperson before attempting
to use it again.
w TO REDUCE THE CHANCE OF ELECTRICAL
SHOCK:
9 Do not attempt to operate equipment if the
ground fault circuit interrupter reset button
pops out repeatedly during use.
9 Test the ground fault circuit interrupter during
the pre-operation checks according to the
maintenance instructions on page 25.
9 Remember that only receptacles labeled
“Ground Fault Protected” have ground fault
circuit interrupter protection.
1
3
7NJ-9-12A 10/27/03 10:20 AM Page 11
– 12 –
741-001
707-033a
q 707-001
707-037
707-051
AE00845
PRE-OPERATION CHECK
NOTE:
Pre-operation checks should be made each time the
generator is used.
w The engine and muffler will be very hot after the
engine has been run.
Avoid touching the engine and muffler while they
are still hot with any part of your body or clothing
during inspection or repair.
AE00856
FUEL
Make sure there is sufficient fuel in the tank.
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number ((R
+ M)/2) of 86 or higher, or research octane number of
91 or higher.
1 Fuel level gauge
w 9 Fuel is highly flammable and poisonous.
Check “SAFETY INFORMATION” (See page 5)
carefully before refueling.
9 Do not fill above the top of the fuel filter or it
may overflow when the fuel heats up later and
expands.
9 Wipe up any spilled fuel immediately.
9 After refueling, make sure the tank cap is tightened securely.
Recommended fuel:
Unleaded gasoline
Fuel tank capacity:
Total:
EF1600/EF2600
12.0 L (2.64 Imp gal, 3.17 US gal)
YG2600
19.0 L (4.18 Imp gal, 5.02 US gal)
“F” Full
“E” Empty
7NJ-9-12A 10/27/03 10:20 AM Page 12
– 13 –
700-068
700-110
q 700-065
0°C 25°C
80°F32°F
A YAMALUBE 4(10W-30)
D SAE 10W C SAE #20 B SAE #30
700-006
741-029a
AE00222
ENGINE OIL
Make sure the engine oil is at the upper level of the oil
filler hole.
Add oil as necessary.
1 Upper level
NOTE:
Recommended engine oil classification:
API Service “SE” or “SF”.
cC The generator has been shipped without engine
oil. Fill with oil or it will not start.
AE00241
GROUND (Earth)
Make sure to ground (earth) the generator.
Check "SAFETY INFORMATION" on page 6.
Recommended oil:
å YAMALUBE 4 (10W-30) or SAE 10W-30
type SE motor oil
∫ SAE #30
ç SAE #20
∂ SAE 10W
Engine oil quantity:
0.6 L (0.53 lmp qt, 0.63 US qt)
7NJ-9-12A 10/27/03 10:20 AM Page 13
– 14 –
761-027
q 763-086e
OFF
ON
705-037q
763-084h
q 701-025a
q AE00955
OPERATION
NOTE:
The generator has been shipped without engine oil.
Fill with oil or it will not start.
1 Upper level
AE00854
STARTING THE ENGINE
NOTE:
9 Before starting the engine, do not connect any
electric devices.
9 Turn the AC switch (N.F.B.) to the “OFF” position.
1 3 “OFF”
1. Turn the fuel cock lever to the “ON” position.
1 “ON”
2. Turn the engine switch to the “ON” position.
1 7 “ON”
3. Turn the choke lever to the “1” position.
1 Choke lever
NOTE:
The choke is not required to start a warm engine.
Turn the choke lever to the operating position.
700-006a
q 7NJ-9-12A 10/27/03 10:21 AM Page 14
– 15 –
4. Pull slowly on the recoil starter until it is engaged,
then pull it briskly.
5. After the engine starts, warm up the engine until
the engine does not stop when the choke lever is
returned to the operating position.
6. Turn the choke lever back to the operating position.
1 Operating position
704-010
701-025
q NOTE:
9 “–” means below.
9 Application wattage indicates when each apparatus is used by itself.
cC Be sure the total load is within generator rated output otherwise generator damage will occur.
NOTE:
Some precision equipment is voltage sensitive and
may require a more uniform voltage supply than
portable generators provide. Examples include some
medical equipment, personal computers, and some
inverters that sense peak and RMS voltage values.
Consult the precision-equipment vendor before relying
on any portable generator to provide power to such
equipment.
AE00343
APPLICATION RANGE
AC
Power factor 1 0.8–0.95
0.4–0.75
(Efficiency 0.85)
EF1600 –1,400W –1,120W –480W
EF2600
YG2600
–2,300W –1,840W –780W
779-006a 779-006c 779-006b
7NJ-9-12A 10/27/03 10:21 AM Page 15
– 16 –
AE00851
CONNECTION
Alternating Current (AC)
cC 9 Be sure all electric devices including the lines
and plug connections are in good condition
before connection to the generator.
9 Be sure any electric devices are turned off
before plugging it in.
9 Be sure the total load is within generator rated
output.
9 Be sure the receptacle load current is within
receptacle rated current.
1. Wind the power lead 2 or 3 turns around frame.
å EF1600/EF2600
∫ YG2600
2. Start the engine.
761-028
q 763-095
OFF
ON
3. Plug into AC receptacle.
4. Make sure the voltage meter indicates the rated
voltage (for EF1600/EF2600) or the pilot light is on
(for YG2600).
å Voltage meter
∫ Pilot light
5. Turn the AC switch (N.F.B.) to the “ON” position
and turn on any electric devices.
1 I “ON”
cC Reduce the load to the specified generator rated
output if an AC switch turns off. If it turns off
again, consult a Yamaha dealer.
761-029
A B
779-028
A B
7NJ-9-12A 10/27/03 10:21 AM Page 16
– 17 –
763-085e
q 705-038
q AE00852
STOPPING THE ENGINE
NOTE:
9 Turn off any electric devices.
9 Turn the AC switch (N.F.B.) to the “OFF” position.
2. Turn the engine switch to the “STOP” position.
1 5 “STOP”
3. Turn the fuel cock lever to “OFF”.
1 “OFF”
q 763-094a
1 3 “OFF”
1. Disconnect any electric devices.
7NJ-9-12A 10/27/03 10:21 AM Page 17
– 18 –
* : It is recommended that these items be serviced by a Yamaha dealer.
** : Related to emission control system.
AE00401
PERIODIC MAINTENANCE
AE00403
MAINTENANCE CHART
Regular maintenance is most important for best performance and safe operation.
w Stop the engine before starting maintenance work.
No. Item Remarks
Pre-Operation
check
(daily)
Initial Every
1
month
or 20 Hr
3
months
or 50 Hr
6
months
or 100 Hr
12
months
or 300 Hr
Check condition.
1. **
Adjust gap and
0Spark Plug
clean. Replace if
necessary.
**
Check and adjust
2.* Valve Clearance when engine is 0
cold.
Check breather
** hose for cracks or
03.* Crankcase
damage. Replacebreather system
if necessary.
4.* **
Check and adjust
0Idle speed
engine idle speed.
Check for leakage.
Retighten or
0
**
*replace gasket
5. Exhaust System
if necessary.
Check muffler
screen and spark
arrester. Clean/ 0
replace if
necessary.
Check oil level 0
6. Engine Oil
Replace 0 0
** Clean.
7. Air Filter Replace if 0
necessary.
7NJ-9-12B 10/27/03 9:59 AM Page 18
– 19 –
* : It is recommended that these items be serviced by a Yamaha dealer.
** : Related to emission control system.
cC Use only Yamaha specified genuine parts for replacement. Ask an authorized
Yamaha dealer for further attention.
Clean fuel cock
8. Fuel Filter
and fuel tank
0
filter. Replace if
necessary.
Check fuel hose
9. Fuel Line
for crack or da0
mage. *Replace
if necessary.
10. **
Check choke
0Choke lever
operation.
11. Cooling System
Check for fan
0
damage.
12. Starting System
Check recoil
0
starter operation.
13.* **
More frequently
0Decarbonization
if necessary.
Check the voltage
meter (for EF1600/
14. Generation EF2600) or pilot 0
light comes on
(for YG2600).
Check operation.
15. G.F.C.I. receptacle *Repair if 0
necessary.
Check all fittings
16.*
Fittings/ and fasteners.
0
Fasteners Correct if
necessary.
No. Item Remarks
Pre-Operation
check
(daily)
Initial Every
1
month
or 20 Hr
3
months
or 50 Hr
6
months
or 100 Hr
12
months
or 300 Hr
7NJ-9-12B 10/27/03 9:59 AM Page 19
– 20 –
760-005a
a 760-001a
AE00423
SPARK PLUG INSPECTION
You should periodically remove and inspect the spark
plug.
1. Check for discoloration and remove the carbon.
2. Check the spark plug type and gap.
a Gap
3. Install the spark plug.
AE00431
CARBURETOR ADJUSTMENT
The carburetor is a vital part of the engine. Adjusting
should be left to a Yamaha dealer with the professional knowledge, specialized data, and equipment to do
so properly.
Standard electrode color:
Tan Color
Standard Spark Plug:
BPR4ES (NGK)
Spark Plug Gap:
0.7–0.8 mm (0.028–0.031 in)
Spark Plug Torque:
20 N•m (2 kgf•m, 14 lbf•ft)
7NJ-9-12B 10/27/03 9:59 AM Page 20
– 21 –
q e 700-067
w 700-006a
q 700-065
0°C 25°C
80°F32°F
A YAMALUBE 4(10W-30)
D SAE 10W C SAE #20 B SAE #30
AE00412
ENGINE OIL REPLACEMENT
1. Place the machine on a level surface and warm
up the engine for several minutes.
Then stop the engine.
2. Remove the oil filler cap.
3. Place an oil pan under the engine. Remove the oil
drain plug so that the oil can be completely
drained.
4. Check the drain plug, gasket, oil filler cap and Oring.
If damaged, replace.
1 Oil drain plug
2 Gasket
3 O-ring
5. Reinstall the oil drain plug.
Drain Plug Torque:
17 N•m (1.7 kgf•m, 12 lbf•ft)
6. Add engine oil to the upper level.
1 Upper level
NOTE:
Recommended engine oil classification:
API Service “SE” or “SF”.
cC Be sure no foreign material enters the crankcase.
Recommended oil:
å YAMALUBE 4 (10W-30) or SAE 10W-30
type SE motor oil
∫ SAE #30
ç SAE #20
∂ SAE 10W
Engine oil quantity:
0.6 L (0.53 Imp qt, 0.63 US qt)
7NJ-9-12B 10/27/03 9:59 AM Page 21
– 22 –
710-037a
AE00451
AIR FILTER
1. Remove the air filter cover and element.
2. Wash the element in solvent and dry.
3. Oil the element and squeeze out excess oil.
The element should be wet but not dripping.
cC Do not wring out the element.
This could cause it to tear.
4. Insert the element into the air filter.
NOTE:
Be sure the element sealing surface matches the air
filter so there is no air leak.
cC The engine should never run without the element;
excessive piston and cylinder wear may result.
w Never use solvent while smoking or in the vicinity
of an open flame.
Recommended oil:
Foam-air-filter oil
or SAE #20 motor oil
7NJ-9-12B 10/27/03 9:59 AM Page 22
– 23 –
A B
A B
A B
705-067
707-043b
q AE00855
FUEL COCK
w Never use or be near fuel and solvent while smoking or in the vicinity of an open flame.
1. Stop the engine.
2. Turn the fuel cock lever to “OFF”.
3. Remove the fuel cock cup and gasket.
4. Clean the cup with solvent and wipe it off.
5. Check the gasket. Replace it if damaged.
6. Reinstall the gasket and fuel cock cup.
w Be sure the fuel cock cup is tightened securely.
å EF1600/EF2600
∫ YG2600
AE00471
FUEL TANK FILTER
1. Remove the fuel tank cap and filter.
1 Filter
2. Clean the filter with solvent. If damaged, replace.
3. Wipe the filter and insert it.
w Be sure the tank cap is tightened securely.
7NJ-9-12B 10/27/03 9:59 AM Page 23
– 24 –
741-001
q w 711-015
711-012b
711-012a
q 711-022
711-050
AE00853
MUFFLER SCREEN AND SPARK ARRESTER
w The engine and muffler will be very hot after the
engine has been run.
Avoid touching the engine and muffler while they
are still hot with any part of your body or clothing
during inspection or repair.
1. Remove the muffler screen.
1 Muffler screen
2 Screw
2. Use a flathead screw driver to pry the spark
arrester out from the muffler.
3. Remove the spark arrester.
1 Spark arrester
4. Remove the carbon deposits on the muffler
screen and spark arrester using a wire brush.
cC When cleaning, use the wire brush lightly to avoid
damaging or scratching of the muffler screen and
spark arrester.
5. Check the muffler screen and spark arrester.
Replace them if damaged.
7NJ-9-12B 10/27/03 9:59 AM Page 24
– 25 –
711-012a
q 711-017a
763-083a
w q
6. Install the spark arrester.
NOTE:
Align the spark arrester projection with the hole in the
muffler pipe.
1 Projection
2 Hole
7. Install the muffler screen.
AE00501
G.F.C.I. RECEPTACLE TEST
(YG2600)
1. Start the engine.
2. Turn the AC switch (N.F.B.) to the “ON” position.
3. Press the test button 1, then check the position of
the reset button 2.
4. If G.F.C.I. operation is correct, push in the reset
button.
If the G.F.C.I. operates incorrectly, consult a
Yamaha dealer.
w Do not operate the generator with a faulty G.F.C.I.
circuit. Electric shock could occur. Have the generator repaired by a qualified mechanic.
G.F.C.I. Reset G.F.C.I. Receptacle
Button Position Operation
after Test
Pop Out 3 Correct
Stay In 4 Incorrect
763-059
3 4
7NJ-9-12B 10/27/03 9:59 AM Page 25
– 26 –
707-001
705-037a
700-006
763-084i
760-009
AE00512
TROUBLESHOOTING
Engine won’t start
1. Fuel systems
No fuel supplied to combustion chamber.
2 No fuel in tank .... Supply fuel.
2 Clogged fuel line .... Clean fuel line.
2 Foreign matter in fuel cock .... Clean fuel cock.
2 Clogged carburetor .... Clean carburetor.
2. Engine oil system
Insufficient
2 Oil level is low .... Add engine oil.
3. Electrical systems
2 Engine switch to “ON”.
Poor spark
2 Spark plug dirty with carbon or wet .... Remove
carbon or wipe spark plug dry.
2 Faulty ignition system .... Consult dealer.
4. Compression
Insufficient
2 Worn out piston and cylinder .... Consult dealer.
2 Loose cylinder head nuts .... Tighten nuts properly.
2 Damaged gasket .... Replace gasket.
7NJ-9-12B 10/27/03 9:59 AM Page 26
– 27 –
P OK
O Clogged
Engine does not
start.
C Does not flicker D Flickers
B
AE00515
A ENGINE DOES NOT START
Turn the engine switch to “ON”, then pull
the recoil starter and check if the oil
warning light flickers.
791-001e
H Pull the recoil starter and check the
spark plug for spark strength.
(See “WARNING”)
791-001b
w 9 To prevent FIRE HAZARDS be
sure fuel is not present in the
spark plug area.
9 To prevent FIRE HAZARDS be
sure to place the spark plug as
far way as possible from the
spark plug hole and carburetor
area.
9 To prevent ELECTRIC SHOCK do
not hold spark plug lead with
hand while testing.
Engine starts.I J
Check the following
9 Fuel cock clogging
9 Air cleaner element
clogging.
N Clean or Replace; Consult a
Yamaha dealer.
Q
R Consult a Yamaha dealer.
K Check the spark plug.
9 Type:
9 Gap:
L Incorrect M OK
Replace or
Adjust Gap.
Clean the spark
plug.
E Check engine oil level.
F OK G Level low
Consult a
Yamaha dealer.
Add engine oil.
791-001d
791-001c
7NJ-9-12B 10/27/03 9:59 AM Page 27
– 28 –
707-038
q w a e r
712-010
AE00601
STORAGE
Long term storage of your machine will require some
preventive procedures to guard against deterioration.
AE00611
DRAIN THE FUEL
1. Drain the fuel tank, fuel cock, and carburetor float
bowl.
a Carburetor drain plug
2. Pour a cup of SAE 10W30 or 20W40 motor oil into
the tank.
3. Shake the tank to coat the inner surfaces thoroughly.
4. Drain off the excess oil.
AE00621
ENGINE
1. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil into the
spark plug hole and reinstall the spark plug. Recoil
start the engine by turning over several times (with
ignition off) to coat the cylinder walls with oil.
2. Pull the recoil starter until you feel compression.
Then stop pulling. (This prevents the cylinder and
valves from rusting).
3. Clean exterior of the generator and apply a rust
inhibitor.
4. Store the generator in a dry, well-ventilated place,
with the cover placed over it.
5. The generator must remain in a vertical position
when stored, carried or operated.
7NJ-9-12B 10/27/03 9:59 AM Page 28
– 29 –
AE00789
EXHAUST EMISSION CONTROL SYSTEM
AND COMPONENTS
Item Acronym
9 CARB. ASSY., LH. & JT., .............................CARB (Carburetor)
CARBURETOR2
9 T.C.I. MAGNETO ASSY. & ..........................EI (Electronic Ignition)
PLUG, SPARK
9 CRANKCASE1 & HEAD, ..............................PCV (Positive Crankcase
CYLINDER1 Ventilation)
9 AIR FILTER ASSY. .......................................ACL (Air Cleaner)
9 MUFF., 2, CAP, NET, WIRE2 &
ARRESTER, SPARK
The above items and the corresponding acronyms are provided in accordance with U.S.
EPA REGULATIONS FOR NEW NONROAD SPARK-IGNITION NONHANDHELD
ENGINES and the CALIFORNIA REGULATIONS FOR 1995 AND LATER SMALL OFF-
ROAD ENGINES.
The acronyms conform to the latest version of the SAE’s recommended practice document J1930, “Diagnostic Acronyms, Terms, and Definitions For Electrical/Electronic
System”.
It is recommended that these items be serviced by a Yamaha dealer.
7NJ-9-12B 10/27/03 9:59 AM Page 29
– 30 –
AE00701
SPECIFICATIONS
AE00702
DIMENSIONS
AE00704
ENGINE
AE00707
GENERATOR
Unit EF1600 EF2600 YG2600
Type Forced air cooled 4-stroke gasoline OHV
Cylinder Arrangement Inclined, 1 cylinder
Displacement cm3 123 171 171
Bore × Stroke mm 56.0 × 50.0 66.0 × 50.0 66.0 × 50.0
(in) (2.20 × 1.97) (2.60 × 1.97) (2.60 × 1.97)
Rated Output kW(HP) r/min 2.0 (2.7)/3,600 3.3 (4.4)/3,600 3.3 (4.4)/3,600
Operation Hours Hr 13.5 9.0 14.0
Fuel Unleaded gasoline
Fuel Tank Capacity L (Imp gal, US gal) 12.0 (2.64, 3.17) 12.0 (2.64, 3.17) 19.0 (4.18, 5.02)
Engine Oil Quantity L (Imp qt, US qt) 0.6 (0.53, 0.63) 0.6 (0.53, 0.63) 0.6 (0.53, 0.63)
Ignition System TCI
Spark Plug: Type BPR4ES (NGK)
Spark Plug: Gap
mm (in)
0.7–0.8 (0.028–0.031)
Noise Level* dB (A) 65 67 67
Unit EF1600 EF2600 YG2600
AC Output
Rated Voltage V 120 120 120
Rated frequency Hz 60 60 60
Rated current A 11.7 19.2 19.2
Rated Output kVA 1.4 2.3 2.3
Safety Device: Type NFB
Unit EF1600 EF2600 YG2600
Overall Length mm (in) 510 (20.1) 510 (20.1) 593 (23.3)
Overall Width mm (in) 415 (16.3) 415 (16.3) 487 (19.2)
Overall Height mm (in) 425 (16.7) 425 (16.7) 534 (21.0)
Dry Weight kg (lb) 38 (83.8) 41 (90.4) 46.5 (102.5)
* : Measured at rated operation from 7 m (23 ft) distance.
7NJ-9-12B 10/27/03 9:59 AM Page 30
– 31 –
AE00751
WIRING DIAGRAM
Generator assembly Control box
1(for EF1600)
Frame earth
Engine
(For EF1600)
1
2
w 4
3 3
q5 6
8
37
9
0
G/Y
G
G
G
G
G
G
G
G
R
BrBr
G
G
G/Y
G/Y
B/W
B/W
L
Y
B/WL Y B B/W B
B
G/Y
R
R
Br R
Br R
Br 770-007
Br G/Y
R
V
1 Rotor assembly
2 Stator assembly
3 AC receptacle
4 AC switch (N.F.B.)
5 Engine switch
6 Condenser
7 Oil level switch
8 Oil warning unit
9 T.C.I. unit
0 Spark plug
q Gound (earth) terminal
w Voltage meter
Color code
B Black
Br Brown
G Green
L Blue
R Red
G/Y Green/Yellow
B/W Black/White
EF1600/EF2600
7NJ-9-12B 10/27/03 9:59 AM Page 31
– 32 –
YG2600
q w r e e
u i y t o !0
!2
!1
Generator assembly
Frame earth
Engine
Control box
G/Y
G
G
G
G
G
G
G
G
G/Y
G/Y
R
BrBr
G
G
G/Y
G/Y
B/W
B/W
L
Y
B/WLY B B/W B
B
G/Y
G/Y
R
R
Br R
Br R
Br 770-008
1 Rotor assembly
2 Stator assembly
3 AC receptacle
4 AC switch (N.F.B.)
5 Engine switch
6 Condenser
7 Oil level switch
8 Oil warning unit
9 T.C.I. unit
0 Spark plug
q Gound (earth) terminal
w Pilot light
Color code
B Black
Br Brown
G Green
L Blue
R Red
G/Y Green/Yellow
B/W Black/White
7NJ-9-12B 10/27/03 9:59 AM Page 32
– 33 –
AE00795
ENGINE HANGER INSTALLATION
(for YG2600)
794-001
7NJ-9-12B 10/27/03 9:59 AM Page 33
Generator
LIT-19626-01-14 7NJ-28199-12PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
03 908 – 0.4 × 1 !
EF1600
EF2600
YG2600
OWNER’S MANUAL
7NJ-9-12 Hyoshi 10/27/03 9:03 AM Page 1

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