Yamaha EF4500iSE manual

Generator 7XF-28199-10 EF4500iSE O WNER’S MANU AL PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE MACHINE. LIT-19626-01-46 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2008 9 02 – 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 [...]

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. c C[...]

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 .[...]

– 1 – 741-7XFa 741-7XFb 741-7XFc 741-7XFd 741-7XFe 741-7XFf AE00071 SAFETY INFORMA TION 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 [...]

– 2 – 741-7XFg a 741-7XFh 1 794-7XFa 741-7XFi 741-7XFj 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) 9 Avoid operating the engine with a dust cover. 9 Be sure to carry the generator only by its carrying handle(s). 1 Carrying handle(s) (shaded) AE00083 ELECTRIC SHOCK PREVENTION[...]

– 3 – 1 2 1 2 741-7XFk 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 build- ing’s electrical system, a licensed electrician must install an isolati[...]

– 4 – AE00062 LOCA TION OF IMPORT ANT 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 us[...]

– 5 – 35 2 6 WARNING READ THE OWNER ‘ S MANUAL AND ALL LABELS BEFORE OPERATING. q q AVERTISSEMENT 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 [...]

– 6 – DESCRIPTION AE00102 1 Carrying handles (shaded) 2 Fuel tank cap 3 Fuel gauge 4 Muffler 5 Caster lock lever 6 Oil filler cap 7 Oil drain plug 8 Battery AE00103 Control panel 1 Hour meter 2 Power meter 3 AC protector 4 AC receptacle 5 Engine switch 6 Fuel cock knob 7 Ground (Earth) terminal 8 Overload indicator light 9 AC pilot light 0 Oil [...]

763-119 q w e – 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 oi[...]

– 8 – 793-7XFe 1 2 AE00134 AC protector The AC protector 1 trips when total amount of the two receptable 2 loads exceeds 20A. Press the switch to reset the AC protector. 1 I “ Set ” 2 3 “ Reset ” 763-238a 1 2 1 763-7XFf 1 763-7XFg 1 763-7XFc Hour meter The hour meter 1 shows the total number of hours the generator has been run. Power me[...]

– 9 – AE01087 Overload indicator light The overload indicator light 1 comes 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 A[...]

– 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 t[...]

– 11 – 741-7XFl 1 2 707-7XF 707-7XFc 3 4 707-7XFa PREP ARA TION AE00856 Fuel w 9 Fuel is highly flammable and poisonous. Check “ SAFETY INFORMATION ” (See page 1) carefully before filling. 9 Do not overfill the fuel tank, otherwise it may overflow when the fuel warms up and expands. 9 After fill the fuel, make sure the fuel tank cap is tigh[...]

– 12 – – 12 – 3 700-7XFa 700-103c r 0 ° C å YAMALUBE 4 (10W-30 or 10W-40) ∂ SAE 10W ç SAE #20 ∫ SAE #30 32 ° F 25 ° C 80 ° F 700-006 AE00222 Engine oil c C 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 t[...]

– 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- [...]

– 14 – 9. Connect the negative lead (black) 8 to the nega- tive (-) battery terminal 9 . 10. Install the rear cover and tighten the bolts. 8 9 762-7XFd 7XF-28199-10_a 08.1.31 9:19 Page 14[...]

– 15 – AE00845 PRE-OPERA TION 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-oper[...]

– 16 – 761-7XFb 705-073 ON OFF q AE00846 OPERA TION w 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 ven- tilated area. 9 Before starting the engine, do not connect any electric devices. c C The generator has been shipped without engine oil. Do not start th[...]

– 17 – 763-120a q 3. Turn the engine switch to “ START ” . Take your hand off the switch immediately after the engine starts. 1 6 “ START ” c C If the engine fails to start, release the switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the bat- tery. Do not crank the engine more than 5 s[...]

– 18 – 761-7XFb 763-120b q 705-073a ON OFF q 4. Turn the fuel cock knob to “ OFF ” . 1 “ OFF ” 3. Turn the engine switch to “ STOP ” . 1 5 “ STOP ” AE00840 Stopping the engine 1. Turn off any electric devices. 2. Disconnect any electric devices. 7XF-28199-10_a 08.1.31 9:19 Page 18[...]

– 19 – AE00839 Connection Alternating Current (AC) w Be sure any electric devices are turned off before plugging it in. c C 9 Be sure all electric devices including the lines and plug connections are in good condition before connection to the generator. 9 Be sure the total load is within generator rated output. 9 Be sure the receptacle load cur[...]

– 20 – AE00812 Application range When using the generator, make sure the total load is within rated output of a generator. Otherwise, generator damage may occur. AC Power factor 1 0.8 ~ 0.95 0.4 ~ 0.75 (Efficiency 0.85) EF4500iSE – 4,000W – 3,200W – 1,360W NOTE: 9 “–” means below. 9 Application wattage indicates when each device is [...]

– 21 – AE00401 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your generator in the safest and most efficient condition possible. The most impor- tant points of generator inspection, adjustment, and lubrication are explained on the fol- lowing pages. w If you are not familiar[...]

– 22 – *1 ····· Initial replacement of the engine oil is after one month or 20 hours of operation. *2 ····· The air filter element needs to be cleaned more frequently when using in unusually wet or dusty areas. ★ ····· Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser- vice[...]

4. Check the spark plug type and gap a . NOTE: The spark plug gap should be measured with a wire thickness gauge and, if necessary, adjusted to specifi- cation. 5. Install the spark plug. NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4-1/2 turn past finger tight. However, the spar[...]

3. Remove the rubber cap 3 , plastic plug 4 and the oil filler cap 5 . 4. Place an oil pan under the engine. Remove the oil drain bolt 6 so that the oil can be completely drained. 5. Check the drain bolt, gasket 7 , oil filler cap and O-ring 8 . If damaged, replace. 6. Reinstall the oil drain bolt. 1. Place the machine on a level surface and warm u[...]

– 25 – c C Be sure no foreign material enters the crankcase. 8. Install the oil filler cap, the rubber cap and the plastic plug. 9. Install the front cover and tighten the bolts. AE01084 Air filter 1. Remove the bolts 1 , and then pull outward on the areas of front cover 2 shown. 2. Remove the bolts 3 . 1 2 788-7XFa 3 3 788-7XFi 7. Add engine o[...]

– 26 – 3. Remove the air filter cover 1 and foam element 2 . 4. Wash the foam element in solvent and dry it. 5. Oil the foam element and squeeze out excess oil. The foam element should be wet but not dripping. c C Do not wring out the foam element when squeez- ing it. This could cause it to tear. 6. Insert the foam element into the air filter c[...]

– 27 – 741-7XFl 1 2 788-7XFb 1 2 3 711-7XFa 711-7XFb 4 711-7XFc AE01075 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 bolts 1 , and then pul[...]

– 28 – 2 1 711-7XFd 711-7XFe 6. Install the muffler screen and the muffler cap. 7. Install the rear cover and tighten the bolts. 3 . Remove the carbon deposits on the muffler screen and spark arrester using a wire brush. c C When cleaning, use the wire brush lightly to avoid damaging or scratching of the muffler screen and spark arrester. 4. Ch[...]

– 29 – 707-043b q AE00471 Fuel tank filter w Never use or be near fuel and solvent while smok- ing or in the vicinity of an open flame. 1. Remove the fuel tank cap and filter 1 . 2. Clean the filter with gasoline. If damaged, replace it. 3. Wipe the filter and install it. 4. Install the fuel tank cap. w Be sure the fuel tank cap is tightened se[...]

– 30 – 762-012 AE00842 Battery This generator is equipped with a sealed type (MF) battery, which does not require any maintenance. There is no need to check the electrolyte or to add dis- tilled water. w Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric (sul- phuric) acid. Avoid contact with skin, E[...]

2. Replace the fuse with one of proper amperage. NOTE: If the fuse immediately blows again, consult a Yamaha dealer. 3. Install the front cover and tighten the bolts. – 31 – 1 2 788-7XFa 779-7XF AE01077 Fuse replacement w Be sure to use specified fuse. A wrong fuse will cause electrical system damage and A FIRE HAZ- ARD. c C Be sure the engine [...]

– 32 – AE00601 ST ORA GE Long term storage of your machine will require some preventive procedures to guard against deterioration. AE01056 Drain the fuel 1. Remove the fuel tank cap. Extract the fuel from the fuel tank into an approved gasoline container using a commercially available hand siphon. Then, install the fuel tank cap. w Fuel is high[...]

– 33 – 762-003 AE01086 Battery 1. Remove the battery. 2. Store the battery in a cool, dark and dry place and charge it once a month. Do not store the battery in an excessively warm or cold place [i.e., less than 0 ° C (30 ° F) or more than 30 ° C (90 ° F)]. w 9 Disconnect the negative lead (black) first, then the positive lead (red) from th[...]

– 34 – 707-7XFc 705-073c ON OFF 700-006 760-009 AE00512 TROUBLESHOO TING Engine won ’ t start 1. Fuel systems No fuel supplied to combustion chamber. 2 No fuel in tank .... Supply fuel. 2 Fuel in tank .... Fuel cock knob to “ ON ” . 2 Clogged fuel line .... Clean fuel line. 2 Clogged carburetor .... Clean carburetor. 2. Engine oil system [...]

– 35 – AE00515 Generator won ’ t produce power • Safety device (AC protector) to "Reset" ···· Press the AC protector to “ Set ” . A ENGINE DOES NOT START B Turn the engine switch to “ ON ” , then turn the engine switch to “ START ” . And check if the starter motor cranks. C Cranks D Does not crank F Turn the engine[...]

– 36 – Faulty battery and/or starter motor. Consult a Yamaha dealer. E I Check engine oil level. J OK K Level low Consult a Yamaha dealer. Add engine oil. O Check the spark plug. 9 Type: 9 Gap: P Incorrect Q OK Replace or Adjust Gap. Clean the spark plug. 7XF-28199-10_b 08.1.31 9:21 Page 36[...]

– 37 – Unit EF4500iSE Type Air cooled 4-stroke gasoline OHV Cylinder Arrangement Inclined, 1 cylinder Displacement cm 3 357 Bore × Stroke mm (in) 85.0 × 63.0 (3.35 × 2.48) Operation Hours Hr 7.4 Fuel Unleaded gasoline Fuel Tank Capacity L (US gal, Imp gal) 17.0 (4.49, 3.74) Engine Oil Quantity L (US qt, Imp qt) 1.3 (1.14, 1.37) Ignition Syst[...]

– 38 – AE00012 Identification number records Record your Primary I.D., and serial num- bers 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. PRI-I.D. NUMBER: PRI-I.D. CODE SERIAL No. MODEL Serial NO. 7XF – 7XF-24163-0[...]

– 39 – Yamaha Motor Corporation, U.S.A. hereby war- rants that new Yamaha consumer generators pur- chased from an authorized Yamaha consumer generator dealer in the continental United States will be free from defects in material and workman- ship for the period of time stated herein, subject to certain stated limitations. THE PERIOD OF WARRANTY[...]

– 40 – WARRANTY QUESTIONS AND ANSWERS Q. What costs are my responsibility during the warranty period? A . The customer ’ s responsibility includes all costs of normal maintenance service, non- warranty repairs, accident damages, as well as oil and spark plugs. Q. What are some examples of “ abnormal ” strain, neglect, or abuse? A. These t[...]

– 41 – 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 F[...]

– 42 – — MEMO — 7XF-28199-10_b 08.1.31 9:21 Page 42[...]

– 43 – M Y R B/W L/R R/W R/B B OFF ON START R R B B G/W B/R R/W Or/W Y/W R Y Y Y Y G L Or G/W B/R L/Y L/R L/W Y/W R/W L/W Or/W R L Y Y Y Y G Or R L Y G Or L/W G/W R/W Or/W Y/W L/W L L Or W W W W WW G/R W G/R G/R G/R B/W Or B/W L/Y B/R L/Y L Y Or Br R L/W Y/W R Y B/W R/W R/B G/Y R/L L/G R/W R/B G/Y G/Y Br G/Y G/R Y G/R Y L/W G/Y L/W G/Y L/R G/R [...]

– 44 – 1 Main coil 2 Control unit 3 AC protector (breaker) 4 AC pilot light 5 AC receptacle 6 Overload indicator light 7 Hour meter/power meter 8 Ground (Earth) terminal 9 Rectifier/regulator 0 Engine switch q Speed limiter assembly w Rectifier e Oil warning light r Diode assembly t Fuse y Oil level gauge u T.C.I magneto i Spark plug o T.C.I un[...]

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

Generator 7XF-28199-10 EF4500iSE O WNER’S MANU AL PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE MACHINE. LIT-19626-01-46 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2008 9 02 – 1.0 × 1 ! 7XF-28199-10_hyoshi 08.1.25 9:33 AM Page 1[...]