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3-104

Yamaha Generator Theory & Diagnostics Guide

CONVENTIONAL GENERATOR YG4000D

Содержание EF4500iSE - Inverter Generator

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

Страница 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...

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 34: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 51: ...2 17 Generator Diagnostics...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 76: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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