Yamaha EF4500iSE - Inverter Generator Theory & Diagnostics Manual Download

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Yamaha Generator Theory & Diagnostics Guide

Resistance 250

Terminal: F3-1, 3-5, 3-2, 3-4

500

Terminal: 1-5, 2-4

Throttle valve position:

During assembly:

During engine starting:

Open

Summary of Contents for EF4500iSE - Inverter Generator

Page 1: ...YAMAHA GENERATOR THEORY DIAGNOSTICS GUIDE...

Page 2: ...Corporation U S A December 2008 All rights reserved Any reprinting or unauthorized use without written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A Specificat...

Page 3: ...Y FOR AVR TYPE GENERATORS 2 8 AVR TROUBLESHOOTING CHART 2 16 NON AVR TROUBLESHOOTING CHART 2 17 TROUBLESHOOTING YAMAHA INVERTER GENERATORS 2 18 Ignition System 2 19 Generator System 2 23 Engine Troubl...

Page 4: ......

Page 5: ...how Yamaha Generators work basic troubleshooting techniques and tips for dealership personnel The Importance of Warranty Registration It is important to warranty register every applicable Yamaha produ...

Page 6: ...ing lamp Output indicator Over load indicator USA specification Yamaha inverter generators use a microcomputer controlled sine wave inverter Most inverter generators are in a soundproof case and desig...

Page 7: ...ter circuit further smoothens the sine wave of the AC current and reduces electrical noise Protective functions Overload over current protection device The control unit has similar function to conven...

Page 8: ...d directly to a generator The DC output is controlled only by the capability condition and state of charge of the battery Voltage and Frequency Standards In the U S standard commercial electricity is...

Page 9: ...e magnets generates three phase AC 120V Model AC 135 to 225V 300 to 550 Hz 230V Model AC 260 to 488V 300 to 550Hz s Generator Theory Troubleshooting ontrol not does Condenser Winding Sine Wave Synchro...

Page 10: ...ution during resistance measurement Do not allow the lead wire of the tester to touch the next terminal when measuring the resistance between terminals Caution during assembly To prevent damage to the...

Page 11: ...ime EF3000iSE is able to run for 20 5 hours with 1 4 load with fuel tank full when economy control switch is on With rated load 8 0 hours With 1 4 load 20 5 Hours Refer to Section 3 for model specific...

Page 12: ...ally dangerous situation Instantaneous Frequency Fluctuation Instantaneous Voltage Drop Momentary frequency fluctuation The frequency and voltage fluctuates momen tarily when the load is altered if th...

Page 13: ...neration if a problem occurs with a connected device there is an overload or the inverter control unit overheats the electronic breaker will be activated and interrupt power output to pro tect the gen...

Page 14: ...rocedures The carburetor float bowl should be emptied using the float bowl drain screw located on the float bowl The fuel tank should be full and contain the proper amount of a fuel stabilizer The uni...

Page 15: ...7 5 i 3 2 8 4 1 0 o u u y 5 1 Main coil 2 Sub coil 3 DC coil 4 DC rectifier 5 Control unit 6 AC pilot light 7 AC receptacle 8 Ground Earth terminal 9 Economy control switch 0 Overload indicator light...

Page 16: ...lete when the specific gravity of the battery is 1 26 1 28 Check the specific gravity in every hour or so A 40AH battery of a compact car which is half dis charged will be almost fully charged in abou...

Page 17: ...tage in the CDI in order to charge the condenser In a typical CDI system volt age of approximately 200 400 volts is generated by the charge coil The advantages are the charge coil can be made both lig...

Page 18: ...ver these extra coils become unwanted resistance that reduced generating effi ciency Thus a system has been adopted that auto matically selects the right coil in relation to the engine rpm the low spe...

Page 19: ...erter steps up the battery voltage from 12 volts to 190 volts DC DC converter is automatically activated to increase generator output when the AC output cur rent exceeds 20 amps and the voltage at the...

Page 20: ...m OFF Blink For 10 seconds after shutdown OFF ON Alarm mode Designation of LED Indicators DC DC converter unit is equipped with two indicator lamps LED on the unit When the DC DC converter is activate...

Page 21: ...is function prevents the engine from serious damage The oil warning lamp turns on by attempting to start the engine so as to warn the operator that the engine oil should be replaced or refilled TCI Ig...

Page 22: ...to facilitate engine starting operation While the engine is stationary or running at very low speed a pin provided in the camshaft is projected above the basic circle of exhaust cam lobe The pin conse...

Page 23: ...erminal voltage is less than 11 5V internal resistance may be high due to long term storage charge the battery by following the procedure It is necessary to adjust the voltmeter so that the standard c...

Page 24: ...ke or surge in current Unlike a fuse how ever the NFB can be reset Electronic Breaker An electronic circuit breaker automatically cuts off the current when the output voltage exceeds the maximum capac...

Page 25: ...2300 Coffee Maker 1000 0 Toaster 2 slice 1100 0 Toaster 4 slice 1650 0 Electric Skillet 1500 0 Electric Range 6 in element 1500 0 Electric Range 8 in element 2100 0 Freezer 2500 2200 KITCHEN SUB TOTA...

Page 26: ...Machine 750 Jigsaw 800 Coffee Maker 850 Electric Weed Trimmer 1000 Router 1000 Belt Sander 1000 2 Slice Toaster 1100 Vacuum Cleaner 1100 Disc Sander 1200 Chain Saw 1200 13 500 btu RV Air Conditioner 1...

Page 27: ...Miter Saw 1500 16 Beam Saw 1500 14 Cut off Saw 1500 9 Disc Grinder 1800 12 Concrete Cutter 1800 7 1 4 Circular Saw 2000 Air Compressor 2000 Submersible Pump 1 HP 2000 Concrete Vibrator 2000 Air Condit...

Page 28: ...A 53 58 dBA 60 60 Normal Speech EF3000iSE EF3000iSEB 51 57 dBA 50 50 Business Office EF1000iS 47 57 dBA 35 35 Soft Whisper 25 25 Bedroom at Night INDUSTRIAL DECIBEL LEVEL COMPARISONS GENERAL ESTIMATES...

Page 29: ...al Series Generators Model Introduction Year Unlike Motorsports products Yamaha does not use or recognize model years for generators Instead Yamaha uses the term Model Introduction Year MIY to help id...

Page 30: ...r delivery when a fault or short to ground is detected to pre vent electrocution It is a device that interrupts the power flowing through a GFCI receptacle when a proper ground is not present or if wh...

Page 31: ...101 11 USA N100 606 91 3 85 0 83 3 82 5 EF2600 EF2600A 7NJ 7CA 7NJ 14101 10 USA CAN N100 606 91 3 90 0 87 5 87 5 86 3 EF2300 EF2600 EF2600FW 7CA 7DF 7CN E4101 10 OTH JPN USA N100 606 91 3 90 0 87 5 86...

Page 32: ...correct tools will ensure that the problem is fixed right the first time There are 5 important diagnostic tools the Service Department should have to properly diagnose and repair most Inverter and Co...

Page 33: ...one of a kind meter gives instant accurate readout of amps or watts used by common cord connected household appliances and lights It is a useful consumer tool for rightsizing a generator or determing...

Page 34: ......

Page 35: ...000 watts and are referred to as non AVR type models The second method is through the use of a perma nent magnet within the Exciter Field Coil These are models that are rated at 4 000 watts or higher...

Page 36: ...the cycle of electricity As the rotor turns the residual magnetism creates a small amount of AC voltage within the sub coil That voltage is then sent back and forth between the condenser and the sub c...

Page 37: ...sub coil wires on most conventional models are green but check the manual of the model you are working on for exact colors and con nectors With the generator running apply a 12 volt DC power source t...

Page 38: ...nge to check their resistance Measure the sub coils resistance between the two Green wires Next measure the main coils resistance between the Brown and Red wires Even if the stator passes both of thes...

Page 39: ...en circuit Any resistance reading at all indicates a bad coil In the generator s stator assembly there are actually two individual coils wrapped separately around the same core This is where the short...

Page 40: ...e cause of the problem For the next test it will be necessary to remove the front of the control panel and disconnect the con denser To avoid electrical shock do not touch the terminals of the condens...

Page 41: ...gain noting the reading You should have continuity or a resistance reading in one direction but not in the other direc tion The diode is bad if you have continuity in both direc tions or an open circu...

Page 42: ...begins with a small permanent magnet inside the Exciter Field Coil as opposed to residual magnetism in the rotor on non AVR types When the engine begins to turn a small amount of AC voltage is genera...

Page 43: ...this type of generator They are the AVR circuit board Exciter Field Coil and the Exciter Armature Coil The AVR circuit board makes it possible to hold a more constant voltage even if there is some fl...

Page 44: ...t not at the receptacle then it is a wiring or control box problem And if it is not OK there then the problem is in the generator unit As with the non AVR type perform the normal resis tance test shor...

Page 45: ...Now do the short to ground test on all three of these coils Remember we want to see an open circuit on a good component Br R SUB COIL SHORT TO GROUND TEST EXCITER FIELD COIL SHORT TO GROUND TEST MAIN...

Page 46: ...the knob is turned from one end of it s scale to the other If the voltage adjuster shows an open circuit through out the scale or at any one point in the scale it should be replaced It should also be...

Page 47: ...nd short to ground If the problem was not with any of these compo nents it will then be necessary to replace the AVR circuit board Correctly following these procedures should have revealed the problem...

Page 48: ...this type is that it is not necessary to remove the rotor from the gen erator assembly to test it This is because there are no diodes soldered inside and the windings can be tested through the slip r...

Page 49: ...lip rings and the other meter lead on the core of the rotor You should have an open circuit Any resistance reading would mean the windings are contacting the core and the rotor must be replaced The la...

Page 50: ...2 16 Yamaha Generator Theory Diagnostics Guide...

Page 51: ...2 17 Generator Diagnostics...

Page 52: ...mining if a Problem is Generator or Engine Related One item of importance when troubleshooting a generator is differentiating between an electrical problem with the generator and a mechanical problem...

Page 53: ...2 19 Inverter Generator Diagnostics...

Page 54: ...2 20 Yamaha Generator Theory Diagnostics Guide...

Page 55: ...1 mm 0 02 0 004 in 6 Engine switch 9 Disconnect the engine switch coupler in the control box 9 Connect the pocket tester 1k to the engine switch terminal Tester lead Black white terminal 1 Tester lea...

Page 56: ...evel switch for continuity Tester lead Blue lead 1 Tester lead Ground 2 1 2 1 2 Continuity Correct No continuity Correct 8 Wire harness 9 Check the terminal of the connector for con tamination rust or...

Page 57: ...age inspection 9 Connect Brown Green R S Green Brown S T and Brown Brown R T leads 9 Start the engine then measure the voltage Tester range AC300V GOOD TOO LOW DOES NOT GENERATE AC coil 1 W Or W W W W...

Page 58: ...tic force is weak Replace the magneto rotor AC coil 2 resistance inspection 9 Stop the engine 9 Measure the resistance between White Orange R S Orange White S T and White White R T leads Tester range...

Page 59: ...er to THROTTLE CONTROL SYSTEM in CHAPTER 6 Main coil AC voltage inspection 9 Start the engine 9 Connect the pocket tester to the White leads 9 Measure the voltage Tester range AC 300 V GOOD TOO LOW DO...

Page 60: ...L 1 Sub coil AC voltage 13 0 18 0 V at 20 C 68 F Magnetic force is weak Replace the magneto rotor Sub coil resistance inspection 9 Stop the engine 9 Measure the resistance between the White Orange lea...

Page 61: ...age inspection 9 Connect Blue leads 9 Start the engine then measure the voltage Tester range DC 20V GOOD TOO LOW DOES NOT GENERATE L L L L DC coil DC voltage 13 5 23 0 V at 20 C 68 F Replace the recti...

Page 62: ...g light oil warning unit or oil level switch Add Add Replace Set to ON Clean or replace fuel pump Clean or replace fuel cock Replace the fuel TCI unit Clean or replace Remove spark plug attach it to s...

Page 63: ...T OF GOOD SPECIFICATION Check valve face and valve seat for wear GOOD WEAR Resurface or replace Check if the marks on the crankshaft and camshaft are aligned GOOD NO GOOD Correct or replace Check if t...

Page 64: ...dam aged carburetor joint or gasket GOOD NO GOOD 9 Tighten the carburetor bolts securely 9 R e p l a c e carburetor joint or gas ket with a new one Measure valve clear ance GOOD OUT OF SPECIFICATION...

Page 65: ...n due to a damaged throttle shaft seal carburetor joint or gasket GOOD NO GOOD Disassemble or replace Check compression using compression gauge GOOD TOO HIGH TOO LOW Decarbonize combustion chamber if...

Page 66: ...operating condition STABLE UNSTABLE Resurface or replace Check for air suction due to a damaged throttle shaft seal carburetor joint or gasket GOOD NO GOOD Disassemble or replace Check if slow or mai...

Page 67: ...2 33 Inverter Generator Diagnostics the Model s Service Manual Resistance 250 Terminal F3 1 3 5 3 2 3 4 500 Terminal 1 5 2 4 Throttle valve position During assembly Close During engine starting Open...

Page 68: ...not increase when economy control switch is set to ON Check AC output GOOD NO GOOD Refer to GENERATOR SYSTEM in CHAPTER 5 Rotate the shaft of the throttle control motor GOOD NO GOOD Replace the thrott...

Page 69: ...t tester YU 03112 C 90890 03112 Inductive self powered tachome ter YU 8036 B Engine tachometer 90890 03113 90793 80009 90793 80032 CONTINUITY 1 Fuse Remove the fuse Connect the pocket tester 1 to the...

Page 70: ...voltage 12 16 V 1 2 SWL4120J 1 2 SWL4120 MEETS SPECIFICATION Properly connect the charging system GOOD 4 Charging coil resistance Disconnect the charging coil connector Connect the pocket tester 1 to...

Page 71: ...fier for continuity Normal Tester positive lead White 1 Tester negative lead Red 2 Continuity Tester positive lead Red 1 Tester negative lead White 2 No Continu ity 1 2 SWL4135 NO CONTINUITY Replace t...

Page 72: ...6 B Engine tachometer 90890 03113 90793 80009 90793 80032 Pocket tester YU 03112 C 90890 03112 1 Fuse 9 Remove the fuse 9 Connect the pocket tester 1 to the fuse 9 Check the fuse for continuity Replac...

Page 73: ...gine switch connector 9 Connect the jumper lead to the starter relay connector terminals 9 Check the starter motor operation 1 Jumper lead MOVES DOES NOT MOVE MOVES DOES NOT MOVE Repair and or replace...

Page 74: ...2 40 Yamaha Generator Theory Diagnostics Guide Resistance 250 Terminal F3 1 3 5 3 2 3 4 500 Terminal 1 5 2 4 Throttle valve position During assembly Close During engine starting Open...

Page 75: ...Check the connections of the wire harness connec tors and couplers and the wires for an open circuit or short circuit GOOD NO GOOD Correct or replace Checking steps 1 Conect the pocket tester 1k to t...

Page 76: ......

Page 77: ...l series by wattage output smallest to largest The experienced technician who is familiar with Yamaha generator maintenance diagnostic and repair procedures can get the necessary specifica tions to do...

Page 78: ...Pilot light Green 5 Oil warning light Red 6 Generator assembly 7 Engine switch 8 Economy switch 9 DC circuit breaker 0 AC receptacle 7 5 A 2 q DC receptacle 12 V 8 A w Spark plug cap e High tension c...

Page 79: ...C coil 1 AC 2 AC coil 2 AC 3 DC charge coil 4 Generator assembly 5 Rectifier 6 Control unit assembly 7 Pilot light Green 8 AC receptacle 7 5A 2 9 Economy switch 0 Overload warning light Red q DC circu...

Page 80: ...o 8 2 1 Rated output 60 Hz kW PS 5 000 r min 1 21 1 65 Rated engine speed r min 5 000 Operating hours 60 Hz Hrs W no load 12 0 W rated load 4 3 Fuel Unleaded regular gasoline Fuel tank capacity L lmp...

Page 81: ...ated voltage V 120 Frequency Hz 60 Rated output kVA 0 9 Rated current A 7 5 Safety device type AC Electronic no fuse breaker DC Circuit breaker No fuse breaker Rated engine speed r min 5 000 Voltage r...

Page 82: ...0 03 0 07 End gap 0 10 0 3 0 0039 0 0118 0 6 0 0236 Side clearance 0 06 0 11 0 002 0 004 0 15 0 006 OIl ring Type Solid Dimensions B T 1 5 1 9 0 059 0 075 End gap 0 2 0 7 0 0078 0 0275 0 9 0 0354 Cyli...

Page 83: ...3 94 3 96 0 155 0 156 3 90 0 153 Valve face contact width D IN 0 8 0 03 1 8 0 07 EX 0 8 0 03 1 8 0 07 Valve stem runout limit 0 01 0 0004 90 Valve guide Guide inside diameter IN 4 0 0 157 EX 4 0 0 15...

Page 84: ...Type manufacture BV15 11 MIKUNI I D mark 7VV 00 Bore size 11 0 433 Main jet 62 5 Main air jet 1 3 0 051 Pilot air jet 0 9 0 004 Pilot outlet 0 8 0 031 Valve seat size 1 5 0 059 Main nozzle 2H Pilot je...

Page 85: ...e AC coil 1 20 0 47 Br G R S G Br S T Br Br R T With coupler disconnected AC coil 2 20 0 17 W Or R S Or W S T W W R T With coupler disconnected DC coil 20 0 07 Blue Blue Electrical Ignition system TCI...

Page 86: ...ed 4 Pilot light Green 5 Overload warning light Red 6 AC receptacle 20 A 2 7 DC circuit breaker 8 DC receptacle 12 V 8 A 9 Ground terminal 0 TCI unit q Control unit assembly w Rectifier e Generator as...

Page 87: ...AC coil 2 DC charge coil 3 Sub coil 4 Rectifier 5 Generator assembly 6 Control unit assembly 7 Pilot light Green 8 Twin tech parallel running termi nal 9 AC receptacle 20A 2 0 Control box q Ground ter...

Page 88: ...ut 60 Hz kW PS 5 000 r min 2 5 3 4 Rated engine speed r min 3 200 Operating hours 60 Hz Hrs 1 4 rated load 8 6 W rated load 5 0 Fuel Unleaded regular gasoline Fuel tank capacity L lmp gal US gal 6 0 1...

Page 89: ...ted voltage V 120 Frequency Hz 60 Rated output kVA 2 0 Rated current A 16 7 Safety device type AC Electronic no fuse breaker DC Circuit breaker No fuse breaker Rated engine speed r min 3 200 Voltage r...

Page 90: ...s B T 1 5 2 7 0 059 0 106 End gap 0 2 0 4 0 008 0 016 0 9 0 0354 Side clearance 0 02 0 06 0 0008 0 0024 0 1 0 0039 OIl ring Type Solid Dimensions B T 2 5 2 7 0 098 0 106 End gap 0 2 0 4 0 008 0 016 0...

Page 91: ...length C IN 65 9 2 59 EX 66 2 2 61 Valve face contact width D IN 0 7 0 03 1 7 0 067 EX 0 7 0 03 1 7 0 067 Valve stem runout limit 0 01 0 0004 90 Valve guide Guide inside diameter IN 5 5 0 22 5 4 0 21...

Page 92: ...e manufacture BV20 15 MIKUNI I D mark 7CF 10 Bore size 15 0 5906 Main jet 86 3 Main air jet 1 8 0 0709 Pilot air jet 1 1 0 0433 Pilot outlet 0 9 0 0354 Valve seat size 1 8 0 0709 Main nozzle 31B Pilot...

Page 93: ...oltage V r min 17 0 23 0 2 600 Coil resistance Main coil 20 1 22 Br G R S G Br S T Br Br R T With coupler disconnected Sub coil 20 0 19 W Or R S Or W S T W W R T With coupler disconnected DC coil W 20...

Page 94: ...ELECTRICAL COMPONENTS 1 Oil warning unit 2 TCI unit 3 Spark plug 4 Condenser 5 Stator assembly 6 Rotor assembly 7 Oil level switch 8 G F C I receptacle 9 AC switch NFB 0 Voltmeter q Engine switch w Oi...

Page 95: ...w 7 3 770 053a CIRCUIT DIAGRAM ELEC 1 Rotor assembly 2 Stator assembly 3 Voltmeter 4 AC switch NFB 5 G F C I receptacle 6 AC receptacle 7 Ground earth terminal 8 Engine switch 9 Condenser 0 Oil warnin...

Page 96: ...171 Bore Stroke mm in 66 0 50 0 2 60 1 97 Compression ratio 8 5 1 Rated output kW PS 3600 r min 3 3 4 4 Rated engine speed r min 3600 Operating hours Hrs 9 0 Fuel Unleaded regular gasoline Fuel tank...

Page 97: ...ncy Hz 60 Rated output kVA 2 3 Rated current A 19 2 Safety device system NFB G F C I Excitation Self magnetization Initial excitation Residual magnetization AC voltage fluctuation Less than 10 AC freq...

Page 98: ...imit 0 1 0 0004 Cam dimension A 26 9 1 059 0 05 0 002 26 8 1 055 0 05 0 002 B 22 025 0 867 0 05 0 002 21 925 0 863 0 05 0 002 Carburetor mm in Type Quantity BV20 1 I D mark 7NJ 10 Bore size 15 0 590 M...

Page 99: ...ndard Limit Generator Coil resistance 20 Main coil 0 84 Red Brown Sub coil 1 6 Green Green Rotor coil 1 8 Electrical Ignition system TCI Ignition timing BTDC 23 3 3600 r min TCI Primary coil resistanc...

Page 100: ...B Y B W B W Br Br Br Br Br Br R R R G Y G Y R 1 23 6 5 4 8 7 1 Engine switch 2 Oil warning light 3 Voltmeter 4 AC switch NFB 5 G F C I receptacle 6 AC receptacle 7 Condenser 8 Oil warning unit Control...

Page 101: ...3 25 Current Model Specifications and Wiring Diagrams EF2800i INVERTER GENERATOR EF2800i...

Page 102: ...3 26 Yamaha Generator Theory Diagnostics Guide EF2800i WIRING DIAGRAM...

Page 103: ...3 27 Current Model Specifications and Wiring Diagrams EF2800i 5W 30...

Page 104: ...3 28 Yamaha Generator Theory Diagnostics Guide...

Page 105: ...3 29 Current Model Specifications and Wiring Diagrams EF2800i...

Page 106: ...3 30 Yamaha Generator Theory Diagnostics Guide...

Page 107: ...3 31 Current Model Specifications and Wiring Diagrams EF2800i...

Page 108: ...3 32 Yamaha Generator Theory Diagnostics Guide...

Page 109: ...wheel magneto 0 Power unit A TCI unit B Spark plug C Throttle control motor D DC rectifier E Main switch F Economy switch G Engine speed limiter oil level warning unit H DC receptacle 12 V 12 A I AC r...

Page 110: ...ent L cm3 0 171 171 Bore Stroke mm in 66 0 50 0 2 60 1 97 Compression ratio 8 5 1 Standard compression pressure kPa kg cm2 psi 400 600 4 6 57 85 Rated output 60 Hz kW PS 3 800 r min 3 5 4 7 Operating...

Page 111: ...Rated output kVA 2 8 Rated current A 23 3 DC output Rated voltage V 12 Rated current A 12 Safety device type AC Electronic no fuse breaker DC Circuit breaker No fuse breaker Engine speed no load r min...

Page 112: ...n pin diameter 15 995 16 000 0 6297 0 6299 Limit 16 043 0 6316 Piston ring mm in Top ring Type Barrel face Dimensions B T 1 5 2 7 0 0591 0 1063 End gap 0 20 0 40 0 0079 0 0157 Limit 0 65 0 0256 Side c...

Page 113: ...0 040 0 0006 0 0016 Limit 0 1 0 0039 Camshaft mm in Camshaft outside diameter Cam dimension IN EX A 26 9 0 05 1 059 0 002 26 68 0 05 1 050 0 002 B 22 0 0 05 0 866 0 002 22 025 0 05 0 867 0 002 Camsha...

Page 114: ...alve spring mm in Free length IN 26 5 1 04 EX 26 5 1 04 Limit IN 25 2 0 99 EX 25 2 0 99 Set length IN 21 6 0 85 EX 21 6 0 85 Set force IN N kg lb 41 9 46 3 4 2 4 6 92 4 102 1 EX N kg lb 41 9 46 3 4 2...

Page 115: ...at 3 600 r min BTDC 23 3 TCI unit Primary coil resistance 20 0 5 Secondary coil resistance 20 11 5 Air gap between TCI unit and flywheel magneto mm in 0 5 0 1 0 020 0 004 Charge coil resistance 20 0...

Page 116: ...e 120 V 20 A 8 AC receptacle 120 V 30 A 9 AC receptacle 120 240 V 20 A 0 Stator assembly A Rotor assembly B Ground terminal C Oil level switch D Spark plug E TCI unit F Condenser G Oil warning unit H...

Page 117: ...3 41 Current Model Specifications and Wiring Diagrams YG4000DE...

Page 118: ...3 42 Yamaha Generator Theory Diagnostics Guide INVERTER GENERATOR EF4000DE...

Page 119: ...3 43 Current Model Specifications and Wiring Diagrams YG4000DE 5W 30...

Page 120: ...3 44 Yamaha Generator Theory Diagnostics Guide...

Page 121: ...3 45 Current Model Specifications and Wiring Diagrams YG4000DE...

Page 122: ...3 46 Yamaha Generator Theory Diagnostics Guide...

Page 123: ...3 47 Current Model Specifications and Wiring Diagrams YG4000DE...

Page 124: ...3 48 Yamaha Generator Theory Diagnostics Guide...

Page 125: ...3 49 Current Model Specifications and Wiring Diagrams YG4000DE...

Page 126: ...3 50 Yamaha Generator Theory Diagnostics Guide INVERTER GENERATOR EF4500iSE...

Page 127: ...3 51 Current Model Specifications and Wiring Diagrams EF4500iSE EF4500iSE WIRING DIAGRAM...

Page 128: ...3 52 Yamaha Generator Theory Diagnostics Guide...

Page 129: ...3 53 Current Model Specifications and Wiring Diagrams EF4500iSE 5W 30...

Page 130: ...3 54 Yamaha Generator Theory Diagnostics Guide...

Page 131: ...3 55 Current Model Specifications and Wiring Diagrams EF4500iSE...

Page 132: ...3 56 Yamaha Generator Theory Diagnostics Guide...

Page 133: ...3 57 Current Model Specifications and Wiring Diagrams EF4500iSE...

Page 134: ...3 58 Yamaha Generator Theory Diagnostics Guide...

Page 135: ...3 59 Current Model Specifications and Wiring Diagrams EF4500iSE...

Page 136: ...3 60 Yamaha Generator Theory Diagnostics Guide...

Page 137: ...20 A 6 AC receptacle 125 V 30 A 7 AC receptacle 125 250 V 20 A 8 AC switch 120 V NFB 9 AC switch 240 V NFB 0 Exciter field coil A Stator assembly B Rotor assembly C Oil level switch D Spark plug E TC...

Page 138: ...DE B Black Br Brown G Green L Blue R Red W White Y Yellow B W Black White G B Green Black G Y Green Yellow G R Green Red L W Blue White R B Red Black R W Red White 1 Rotor assembly 2 Stator assembly 3...

Page 139: ...V forced air cooled Cylinder arrangement 1 Displacement L cm3 0 301 301 Bore Stroke mm in 78 0 63 0 3 07 2 48 Compression ratio 8 1 1 Rated output 60 Hz kW PS 3 600 r min 5 8 7 9 Operating hours 60 Hz...

Page 140: ...Direct connection Rated power factor 1 0 Frequency variation Less than 5 Voltage fluctuation Less than 10 AC output Rated voltage V 120 240 Frequency Hz 60 Rated output kVA 4 5 Rated current A 37 5 1...

Page 141: ...inside diameter 20 000 0 7874 Limit 20 020 0 7882 Piston pin mm in Piston pin diameter 19 995 20 000 0 7872 0 7874 Limit 19 950 0 7854 Piston ring mm in Top ring Type Barrel face Dimensions B T 1 5 3...

Page 142: ...ameter C 35 969 35 984 1 4161 1 4167 Limit 35 9 1 4134 Connecting rod mm in Small end diameter A 20 006 20 020 0 7876 0 7882 Oil clearance 0 006 0 025 0 0002 0 0010 Big end diameter B 36 000 36 015 1...

Page 143: ...76 0 0354 Limit 1 4 0 551 Valve stem runout limit 0 01 0 0004 90 Valve guide Guide inside diameter IN 6 000 6 012 0 2362 0 2367 EX 6 000 6 012 0 2362 0 2367 Stem to guide clearance IN 0 037 0 064 0 00...

Page 144: ...Carburetor heater resistance 10 26 at 23 C 73 F Unit EF5200DE YG5200D Generator Main coil AC voltage with the sub coil coupler connected 120 V Br R V 130 140 240 V Br L V 225 275 Main coil AC voltage...

Page 145: ...between TCI unit and flywheel mm in 0 4 0 6 0 0157 0 0236 Minimum spark gap mm in 6 0 24 Charging coil resistance battery charging W Ground 20 1 3 G R Ground 20 0 9 Economy idle system Economy idle v...

Page 146: ...00DE AC 120 240V 120V 240V 120V AC SW ON OFF 30A 20A ON OFF ECON SW ON OFF STOP ON START A A Y R B W B W Y Y Y Br R Br G Y G Y Br Br B G Y G Y R R Br Br L L L B W Y G Condenser Negative side is indi c...

Page 147: ...3 71 Current Model Specifications and Wiring Diagrams EF6300iSDE INVERTER GENERATOR EF6300iSDE...

Page 148: ...3 72 Yamaha Generator Theory Diagnostics Guide EF6300iSDE WIRING DIAGRAM...

Page 149: ...3 73 Current Model Specifications and Wiring Diagrams EF6300iSDE...

Page 150: ...3 74 Yamaha Generator Theory Diagnostics Guide...

Page 151: ...3 75 Current Model Specifications and Wiring Diagrams EF6300iSDE...

Page 152: ...3 76 Yamaha Generator Theory Diagnostics Guide...

Page 153: ...t 4 Voltage meter 5 AC switch 120 V 20 A NFB 6 AC receptacle 125 V 20 A 7 AC switch 120 V 30 A NFB 8 AC receptacle 125 V 30 A 9 AC receptacle 125 250 V 30 A 0 AC switch 120 V NFB q AC switch 240 V NFB...

Page 154: ...1 g h u y t q EF6600DE 1 Rotor assembly 2 Exciter coil 3 Sub coil 4 Main coil 5 Stator assembly 6 Voltage meter 7 NFB 8 AC receptacle 125 V 20 A 9 AC receptacle 125 V 30 A 0 AC receptacle 125 250 V 3...

Page 155: ...m in 85 0 63 0 3 35 2 48 Compression ratio 8 1 1 Operating hours 60 Hz Hrs 6 8 Fuel Unleaded regular gasoline Fuel tank capacity L Imp gal US gal 23 0 5 06 6 08 Engine oil capacity L Imp qt US qt 1 1...

Page 156: ...t connection Rated power factor 1 Frequency variation Less than 5 Voltage fluctuation Less than 10 AC output Rated voltage V 120 240 Frequency Hz 60 Rated output kVA 6 0 Rated current A 50 0 25 0 Safe...

Page 157: ...it 20 020 0 7882 Piston pin mm in Piston pin diameter 19 995 20 000 0 7872 0 7874 Limit 19 950 0 7854 Piston ring mm in Top ring Type Barrel face Dimensions B T 1 5 3 6 0 059 0 142 End gap 0 20 0 35 0...

Page 158: ...ank pin outside diameter C 35 969 35 984 1 4161 1 4167 Limit 35 9 1 4134 Connecting rod mm in Small end diameter A 20 006 20 020 0 7876 0 7882 Oil clearance 0 006 0 025 0 0002 0 0010 Big end diameter...

Page 159: ...face contact width D IN 0 7 0 9 0 0276 0 0354 EX 0 7 0 9 0 0276 0 0354 Limit IN 1 4 0 0551 EX 1 4 0 0551 Valve seat contact width IN 0 7 0 9 0 0276 0 0354 EX 0 7 0 9 0 0276 0 0354 Limit IN 1 4 0 0551...

Page 160: ...air jet 1 4 1 6 1 4 Pilot air jet 0 9 Pilot outlet 0 9 1 0 0 9 Valve seat size 1 8 2 0 1 8 Main nozzle 106 P 53 A 106 P Pilot jet 50 63 8 50 Throttle valve 120 Float height H 14 9 0 59 Carburetor heat...

Page 161: ...istance K 3 0 7 5 Air gap between TCI unit and flywheel mm in 0 5 0 020 Minimum spark gap mm in 6 0 24 Charging coil resistance battery charging W Ground 20 2 3 2 3 G R Ground 20 1 7 1 1 1 7 Economy i...

Page 162: ...CONTROL BOX EF6600DE B B W R R R R R Y Y Y Y L L L Br Br Br Br Br Br Br Br Br Br Br B W B W G Y G Y G Y G Y A A G Y Condenser Negative side is indi cated in black Economy idle unit Pass the longer bro...

Page 163: ...3 87 Current Model Specifications and Wiring Diagrams EF12000DE CONTROL PANEL SERVICE DATA Clearance Data and Limits EF12000DE...

Page 164: ...3 88 Yamaha Generator Theory Diagnostics Guide EF12000DE...

Page 165: ...3 89 Current Model Specifications and Wiring Diagrams EF12000DE EF12000DE...

Page 166: ...3 90 Yamaha Generator Theory Diagnostics Guide EF12000DE...

Page 167: ...3 91 Current Model Specifications and Wiring Diagrams EF12000DE EF12000DE...

Page 168: ...3 92 Yamaha Generator Theory Diagnostics Guide EF12000DE...

Page 169: ...3 93 Current Model Specifications and Wiring Diagrams EF12000DE EF12000DE...

Page 170: ...3 94 Yamaha Generator Theory Diagnostics Guide CONVENTIONAL GENERATOR EF12000DE Control Box...

Page 171: ...3 95 Current Model Specifications and Wiring Diagrams EF1200DE EF12000DE WIRING DIAGRAM...

Page 172: ...rning light Red 9 Pilot light Green 0 Oil warning light Red A Oil level switch B DC circuit breaker C Spark plug D Throttle control motor E Pulser coil F Magneto rotor G Stator coil assembly H AC CDI...

Page 173: ...1 Main coil 2 Sub coil AC control 3 Charge coil ignition source 4 Generator assembly 5 Control unit 6 Pilot light 7 AC receptacle 20 A GFCI 8 AC receptacle 30 A 9 Ground terminal 0 DC charge coil A Ec...

Page 174: ...4 Rated engine speed r min 3 550 Operating hours 60 Hz Hrs W no load 24 9 W rated load 7 7 Fuel Unleaded regular gasoline Fuel tank capacity L Imp gal US gal 11 2 2 46 2 96 Engine oil capacity L Imp q...

Page 175: ...current A 20 8 Safety device type AC Electronic no fuse breaker DC Circuit breaker No fuse breaker Rated engine speed r min 3 550 Voltage regulation Voltage feed back system Voltage stability Within 1...

Page 176: ...0 6297 0 6299 Limit 15 950 0 6280 Piston ring mm in Top ring Type Barrel face Dimensions B T 1 5 2 7 0 059 0 106 End gap 0 2 0 4 0 008 0 016 Limit 0 9 0 0354 Side clearance 0 04 0 08 0 0016 0 0031 Li...

Page 177: ...clearance 0 015 0 040 0 0006 0 0016 Limit 0 1 0 004 Camshaft mm in Camshaft outside diameter Cam dimension IN EX A 26 9 0 05 1 06 0 002 26 68 0 05 1 05 0 002 Limit 26 75 1 053 26 53 1 044 B 22 0 0 05...

Page 178: ...rod mm in Runout limit 0 5 0 02 Valve spring mm in Free length IN 26 5 1 04 EX 26 5 1 04 Limit IN 25 0 0 98 EX 25 0 0 98 Set length IN 21 6 0 85 EX 21 6 0 85 Set force IN 4 5 kg 9 9 lb EX 4 5 kg 9 9 l...

Page 179: ...th the throttle control motor coupler dis connected 13 5 23 0 2 800 Coil resistance Main coil 10 0 6 Yellow Yellow Sub coil 10 0 14 Orange Orange DC charge coil 10 0 5 Blue Blue Electrical Ignition sy...

Page 180: ...3 104 Yamaha Generator Theory Diagnostics Guide CONVENTIONAL GENERATOR YG4000D...

Page 181: ...3 105 Current Model Specifications and Wiring Diagrams YG4000D...

Page 182: ...3 106 Yamaha Generator Theory Diagnostics Guide YG4000D WIRING DIAGRAM...

Page 183: ...3 107 Current Model Specifications and Wiring Diagrams YG4000D...

Page 184: ...3 108 Yamaha Generator Theory Diagnostics Guide 5W 30...

Page 185: ...3 109 Current Model Specifications and Wiring Diagrams YG4000D...

Page 186: ...3 110 Yamaha Generator Theory Diagnostics Guide...

Page 187: ...3 111 Current Model Specifications and Wiring Diagrams YG4000D...

Page 188: ...3 112 Yamaha Generator Theory Diagnostics Guide...

Page 189: ...3 113 Current Model Specifications and Wiring Diagrams YG4000D...

Page 190: ...3 114 Yamaha Generator Theory Diagnostics Guide...

Page 191: ...le 125 V 20 A GFCI 7 AC receptacle 125 V 20 A 8 AC receptacle 125 V 30 A 9 AC receptacle 125 250 V 20 A 0 AC switch 120 V NFB A AC switch 240 V NFB B Exciter field coil C Stator assembly D Rotor assem...

Page 192: ...G Green L Blue R Red W White Y Yellow B W Black White G Y Green Yellow G R Green Red L W Blue White R B Red Black R W Red White 1 Rotor assembly 2 Stator assembly 3 Main coil 4 Sub coil 5 Exciter fiel...

Page 193: ...V forced air cooled Cylinder arrangement 1 Displacement L cm3 0 301 301 Bore Stroke mm in 78 0 63 0 3 07 2 48 Compression ratio 8 1 1 Rated output 60 Hz kW PS 3 600 r min 5 8 7 9 Operating hours 60 Hz...

Page 194: ...Direct connection Rated power factor 1 0 Frequency variation Less than 5 Voltage fluctuation Less than 10 AC output Rated voltage V 120 240 Frequency Hz 60 Rated output kVA 4 5 Rated current A 37 5 1...

Page 195: ...inside diameter 20 000 0 7874 Limit 20 020 0 7882 Piston pin mm in Piston pin diameter 19 995 20 000 0 7872 0 7874 Limit 19 950 0 7854 Piston ring mm in Top ring Type Barrel face Dimensions B T 1 5 3...

Page 196: ...4 Limit 1 4 0 551 Valve stem runout limit 0 01 0 0004 90 Valve guide Guide inside diameter IN 6 000 6 012 0 2362 0 2367 EX 6 000 6 012 0 2362 0 2367 Stem to guide clearance IN 0 037 0 064 0 00146 0 00...

Page 197: ...3 0 56 Carburetor heater resistance 10 26 at 23 C 73 F Unit EF5200DE YG5200D Generator Main coil AC voltage with the sub coil coupler connected 120 V Br R V 130 140 240 V Br L V 225 275 Main coil AC...

Page 198: ...n TCI unit and flywheel mm in 0 4 0 6 0 0157 0 0236 Minimum spark gap mm in 6 0 24 Charging coil resistance battery charging W Ground 20 1 3 G R Ground 20 0 9 Economy idle system Economy idle voltage...

Page 199: ...V 120V AC SW ON OFF 30A 20A 20A ON OFF ECON SW ON OFF OFF ON STOP ON GFCI A A Y B R B W B W B W Y Y Y Br R Br Br Br G Y G Y G Y R Br R B G Y G Y R Br L L Br Br L Br Br Br B W B B Condenser Negative si...

Page 200: ...B 6 AC receptacle 125 V 20 A GFCI 7 AC switch 120 V 30 A NFB 8 AC receptacle 125 V 30 A 9 AC receptacle 125 250 V 30 A 0 AC switch 120 V 50 A NFB q AC switch 240 V 25 A NFB w Exciter stator assembly e...

Page 201: ...Rotor assembly 2 Exciter field coil 3 Sub coil 4 Main coil 5 Stator assembly 6 Voltage meter 7 NFB 8 AC receptacle 125 V 20 A GFCI 9 AC receptacle 125 V 30 A 0 AC receptacle 125 250 V 30 A q Ground t...

Page 202: ...0 63 0 3 35 2 48 Compression ratio 8 1 1 Operating hours 60 Hz Hrs 6 8 Fuel Unleaded regular gasoline Fuel tank capacity L Imp gal US gal 23 0 5 06 6 08 Engine oil capacity L Imp qt US qt 1 1 0 97 1 1...

Page 203: ...od Direct connection Rated power factor 1 Frequency variation Less than 5 Voltage fluctuation Less than 10 AC output Rated voltage V 120 240 Frequency Hz 60 Rated output kVA 6 0 Rated current A 50 0 2...

Page 204: ...20 0 7882 Piston pin mm in Piston pin diameter 19 995 20 000 0 7872 0 7874 Limit 19 950 0 7854 Piston ring mm in Top ring Type Barrel face Dimensions B T 1 5 3 6 0 059 0 142 End gap 0 20 0 35 0 008 0...

Page 205: ...0016 Crank pin outside diameter C 35 969 35 984 1 4161 1 4167 Limit 35 9 1 4134 Connecting rod mm in Small end diameter A 20 006 20 020 0 7876 0 7882 Oil clearance 0 006 0 025 0 0002 0 0010 Big end d...

Page 206: ...ntact width D IN 0 7 0 9 0 0276 0 0354 EX 0 7 0 9 0 0276 0 0354 Limit IN 1 4 0 0551 EX 1 4 0 0551 Valve seat contact width IN 0 7 0 9 0 0276 0 0354 EX 0 7 0 9 0 0276 0 0354 Limit IN 1 4 0 0551 EX 1 4...

Page 207: ...3 Main air jet 1 4 1 6 1 4 Pilot air jet 0 9 Pilot outlet 0 9 1 0 0 9 Valve seat size 1 8 2 0 1 8 Main nozzle 106 P 53 A 106 P Pilot jet 50 63 8 50 Throttle valve 120 Float height H 14 9 0 59 Carbure...

Page 208: ...K 3 0 7 5 Air gap between TCI unit and flywheel mm in 0 5 0 020 Minimum spark gap mm in 6 0 24 Charging coil resistance battery charging W Ground 20 2 3 2 3 G R Ground 20 1 7 1 1 1 7 Economy idle sys...

Page 209: ...Y Y Y Y Y B W G Y L Br Br Br Br L Br L R Br Br R G Y Br R G Y Br Br Br Br R Br R Y B W B B W L R Condenser Negative side is indi cated in black Economy idle unit Pass the longer brown lead through th...

Page 210: ...Y Y L L L Br Br Br Br Br Br Br Br Br Br Br Br Br B W R W B W L R B W G Y G Y G Y G Y G Y A A Condenser Negative side is indi cated in black Economy idle unit Pass the longer brown lead through the ec...

Page 211: ...AC receptacle 125 V 20 A GFCI 8 AC receptacle 125 V 20 A 9 AC receptacle 125 V 30 A 0 AC receptacle 125 250 V 30 A A AC switch 120 V NFB B AC switch 240 V NFB C Exciter stator assembly D Stator assem...

Page 212: ...bly 2 Generator assembly 3 Main coil 4 Sub coil 5 Exciter field coil 6 Voltage meter 7 AC switch NFB 8 GFCI 125 V 20 A 9 AC receptacle 125 V 20 A 0 AC receptacle 125 V 30 A A AC receptacle 125 250 V 3...

Page 213: ...4 85 187 4 92 202 8 4 stroke OHV forced air cooled 1 0 357 357 85 0 63 0 3 35 2 48 8 1 1 7 1 9 6 6 6 Unleaded regular gasoline 21 0 4 62 5 55 1 1 0 97 1 16 4 stroke engine oil API service classificat...

Page 214: ...e phase synchronous generator Single phase 2 Self magnetization Residual magnetization Direct connection 1 Less than 5 Less than 10 120 240 60 6 0 50 0 25 0 NFB No fuse breaker 3 600 2 350 AVR More th...

Page 215: ...3 3464 84 900 3 3425 10 0 0 4 85 25 3 3563 85 50 3 3661 20 000 0 7874 20 020 0 7882 19 995 20 000 0 7872 0 7874 19 950 0 7854 Barrel face 1 5 3 6 0 059 0 142 0 20 0 35 0 008 0 014 0 9 0 0354 0 04 0 08...

Page 216: ...8 0 032 0 04 0 0016 35 969 35 984 1 4161 1 4167 35 9 1 4134 20 006 20 020 0 7876 0 7882 0 006 0 025 0 0002 0 0010 36 000 36 015 1 4173 1 4179 0 015 0 045 0 0006 0 0018 0 1 0 004 32 55 0 05 1 28 0 002...

Page 217: ...5 9 0 23 5 9 0 23 88 1 3 47 87 9 3 46 0 7 0 9 0 0276 0 0354 0 7 0 9 0 0276 0 0354 1 4 0 551 1 4 0 551 0 7 0 9 0 0276 0 0354 0 7 0 9 0 0276 0 0354 1 4 0 551 1 4 0 551 0 01 0 0004 90 6 000 6 012 0 2362...

Page 218: ...2009 Yamaha Motor Corporation U S A Printed in U S A LIT BKTEC GN 01...

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Yamaha EF4500iSE - Inverter Generator, Theory & Diagnostics Manual

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