2009 Yamaha Generator Theory And Diagnostics Guide – PDF DOWNLOAD

YAMAHA GENERATOR THEORY & DIAGNOSTICS GUIDE

2009 Yamaha Generator Theory and Diagnostics Guide Š2008 by Yamaha Motor 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. Specifications, features and options are subject to change without notice.

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TABLE OF CONTENTS GENERATOR INFORMATION AND THEORY . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1 Importance of Warranty Registrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Gasoline, Ethanol, Propane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Yamaha Inverter and Conventional Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 AC Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 12 Volt DC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Voltage and Frequency Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Yamaha Generator Inverter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Model Name Clarification YG/EF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Model Introduction Year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Extension Cord Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 High Altitude Jetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 Special Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 GENERATOR DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 2 CONVENTIONAL GENERATOR DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Determining if a Problem is Generator or Engine Related . . . . . . . . . . . . . . . . . . . . . 2-1 THEORY FOR NON-AVR TYPE GENERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 THEORY 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 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Throttle Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Electric Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Choke Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 CURRENT MODEL SPECIFICATIONS AND WIRING DIAGRAMS . . . . . . . . . . . . . . . . Section 3 CONSUMER SERIES GENERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Inverter EF1000iS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Inverter EF2400iS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Inverter EF2800i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Conventional EF2600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Inverter EF3000iSE / B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Conventional EF4000DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Inverter EF4500iSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Conventional EF5200DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

Inverter EF6300iSDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71

Conventional EF6600DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78

Conventional EF12000DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87 INDUSTRIAL SERIES GENERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Inverter YG2800i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96

Conventional YG4000D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-104

Conventional YG5200D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115

Conventional YG6600D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125

Conventional YG6600DE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135

Generator Information and Theory Inverter generators differ from conventional generators in many ways. Inverter generators (Yamaha models with Smart Throttle) do not rely on rpm to control frequency (Hz). A highly specialized control unit manages functions such as AC power modification, rpm, circuit breaker protection, overload warning, and electrical output. Inverters do not need to run at 3,600 rpm as most use a 3-phase multi-pole stator. The inverter can produce more electricity with fewer revolutions versus a single-phase conventional generator. Typically, multi-pole coils work in conjunction with numerous permanent magnets to produce higher output at a lower rpm. Less revolutions means higher fuel economy at lower outputs and quieter operation.

GENERATOR INFORMATION AND THEORY Introduction The purpose of this manual is to provide training and information for Yamaha dealers who may not be familiar with Yamaha Generators. It will help build a better understanding of 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 product sold by your dealership. It is essential for customer satisfaction and insures your customer can receive warranty service from an authorized Yamaha dealer should the need arise.

Furthermore, warranty repairs performed on a unit not warranty registered, will not be considered for reimbursement. Warranty registrations also assist Yamaha with contact information in the event of a recall or safety related issue.

Inverter generators also provide very stable and clean power. The AC power produced by the multipole coil is rectified into DC power – the control unit then inverts the DC power back into AC power. This final inversion creates clean, high-quality electricity.

In most cases, the electricity produced by a Yamaha Inverter Generator is cleaner than most commercial/ residential power.

Gasoline, Ethanol, Propane All models of Yamaha generators run on regular gasoline. Up to 10% ethanol is acceptable for running conditions. However, ethanol tends to attract moisture which will lead to poor performance, so it should not be used when storing a generator for more than a few days.

Currently, there are no propane conversion kits available that Yamaha Motor Corporation, U.S.A. supports. Further, Yamaha recommends against the use of any aftermarket generator propane conversion kits.

*

Yamaha Inverter and Conventional Generators The AC power created by conventional generators is known as “raw” power. The electricity produced by the stator (coils) and rotor (magnets) is delivered to the outlet without modification of the AC sine wave.

In addition, conventional generators must run at 3,600 rpm in order to maintain the required 60 Hz cycle. The power generated by a conventional generator depends on a constant engine speed. Any fluctuation of rpm will create peaks (spikes) and valleys in the AC sine wave. Conventional generators rely on large, heavy stators and rotors, which means a heavier generator. Conventional generators are typically less fuel efficient at low output levels because they must run at 3,600 rpm at all times.

HIGH QUALITY AC

*PWM: Pulse Width Modulation is very clean and stable output with a waveform distortion ratio of 2.5% or less. This low distortion ratio means the output is cleaner than most commercial / residential power, making it safe to run sensitive computer equipment, televisions, and microchip-controlled power tools.

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Yamaha Generator Theory & Diagnostics Guide Yamaha inverter generators use a microcomputer-controlled sine wave inverter. Most inverter generators are in a soundproof case, and designed in response to the diverse needs of the market today.

The Yamaha inverter generator supplies high quality electricity equivalent to household power supply.

NOTE: The EF3000iSE is used in this introduction section for explanation purposes.

Air intake

Control panel

Main switch

Service hatch

Exhaust

Economy control switch

Fuel gauge

MF Battery

DC output

AC receptacles

⎧ ⎪ ⎨ ⎪ ⎩

Recoil starter

Fuel tank cap

USA specification Fuel petcock Fuel pet cock

Choke knob

Oil warning lamp Output indicator Over load indicator

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Service hatch

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Generator Information and Theory ■

Power Generation Stage 1

The rectifier circuit converts three- phase AC into DC and it maintains stable DC voltage using a constant voltage circuit.

Stage 2

The constant voltage DC current is stored in a condenser.

Stage 3

The PWM, Pulse Width Modulator, inverter circuit generates a stable sine wave AC current.

Stage 4

The filter circuit further smoothens the sine wave of the AC current and reduces electrical noise.

Throttle motor (stepping motor) The throttle motor receives pulses from the control unit and opens or closes the throttle valve approximately 0.7° per pulse.

STEPPING MOTOR Stepping motor

Protective functions: ■ Overload (over current) protection device

The control unit has similar function to conventional NFB (no fuse breaker). When the output current exceeds a specified amperage, AC output is interrupted.

Functions of the Electronic Governor The inverter control unit is preprogrammed with the ideal engine speed settings in relation to electrical current output. It uses these settings as a cross-ref■ Overheat protection erence with the detected current output to control

When the internal temperature of the control the throttle motor (and consequently the throttle unit becomes abnormally high, AC output is EF3000iSE new model guide 3/14/03 PM Page 4 speed to an optimum level. valve)4:20 to adjust engine interrupted.

Therefore, the engine speed will always be at the appropriate level according to the load on the sys■ Over-voltage protection device tem.

AC output is interrupted when excessive current flows into the generator from an outside power With an inverter generator, even if the engine source causing voltage to rise in the control speed changes it has no effect on the output unit. frequency.

The electronic governor system is maintenance-free as it cannot be adjusted externally.

Other Functions of the Control Unit: Throttle Control – Control unit commands the throttle motor to adjust engine speed automatically in accordance with the amount of the electrical consumption.

THROTTLE CONTROL

Electronic Governor ENGINE rpm DETECTOR

An electronic governor takes the place of a conventional mechanical governor, and opens and closes the carburetor throttle valve electrically.

Components and functions: ■ Inverter control unit

The control unit constantly monitors AC output and adjusts the throttle motor to produce the necessary engine speed.

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Engine

Control unit

Alternator

Recoil starter

Yamaha Generator Theory & Diagnostics Guide Muffler AC OUTPUTS

Reference information: Ferrite magnets are magnetically stable and have a strong coercive force and so do not become demagnetized. While they have excellent corrosion resistance, they are also brittle due to the way they are produced. Great care must be taken when assembling them as jarring or shocks of force can adversely affect their efficiency and/or cause breakage.

There are two levels of output available from Yamaha generators: 1. Peak Output (short period of time).

2. Rated Output (continuous duty).

In normal operation of course, these levels would merge. The built-in Thermal or Nonfuse Breakers (NFB) are designed to protect against harmful overloads, while allowing for these different levels. The length of time the breaker allows the generator to produce a particular level without interrupting the current flow varies. This flexibility permits the generator to be used for a wide variety of applications:

1. The stated peak output is the amount of current that can be utilized for short time periods before the NFB disconnects the output. This model guideduration, 3/14/03 4:20 PM output levelEF3000iSE allows fornew jobs of short requiring maximum output (tool startup).

2. The rated output is the amount of current the generator can supply for continuous operation.

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EF3000iSE/EF3000iSEB

EF3000iSE/EF3000iSEB

12 Volt DC Output Control Unit

The DC output is intended only to charge a 12-volt battery. If any 12-volt devices should be connected to a 12V battery and never to the 12V plug on the generator. It is possible that a device could be damaged if it is connected directly to a generator.

The control unit is a sealed unit.

Functions:

AC power generation Electronic governor (throttle control)

Economy control program

Self-protective function

Over current

Over voltage

High temperature

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 delivered at 110~120 V AC, and 220~240 V AC. The electrical frequency standard is 60 cycles per second (60 Hz).

Multi-pole Alternator Features Used in Inverter Generators The combination of ferrite magnets in the rotor and multi-pole stator provides a compact and high performance alternator.

High-frequency multi-pole alternator features:

CONTROL UNIT Control unit

16-pole rotor 24-pole stator coil 3-phase AC power generation

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Battery

Section Yamaha Generator Inverter System The control unit and multi-pole alternator cooperate to generate AC output. The inverter, controlled by a 16-bit microcomputer, is a Pulse WidthControl Modulation (PWM) sine wave inverter. unit 1. The generator’s output frequency remains unchanged even when the engine speed varies.

2. The output voltage is stable.

3. The output waveform is a sine wave with a distortion ratio of less than 2.5%, equivalent to household electricity.

PRINCIPLES OF POWER GENERATION WITH AN INVERTER PORTABLE GENERATOR

*Synchronous Generator — Theory & Troubleshooting

s Generator — Theory & Troubleshooting *An alternator that uses highly efficient ferrite magnets generates three-phase AC.

• 120V Model: AC 135 to 225V, 300 to 550 Hz Condenser

• 230V Model: AC 260 to 488V, 300 to 550Hz

Winding Sine Wave

THEORY FOR DAMPER WINDINGS For generators with a condensor control (non AVR), the electricity output is not a very high quality sine-wave, but does meet most requirements for "rough use" power demand.

When the generator begins to get a load applied, the sine wave is altered by the load voltage running through the stator and inducing its own magnetic field, which alters CONVENTIONAL SINE WAVE Sine Wave the path of theCondenser rotor coil’sWinding magnetic flux.

The altered flux line distorts the output sine.

ontrol not does "

INVERTER SINE WAVE Inverter Sine Wave

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Resistance 250Ω Terminal: F3-1, 3-5, 3-2, 3-4 500Ω Terminal: 1-5, 2-4 Throttle valve position: During assembly: Close During engine starting: Open

Yamaha Generator Theory & Diagnostics Guide Throttle Motor

2. When changes in voltage cannot be accepted.

Caution during resistance measurement: Do not allow the lead wire of the tester to touch the next terminal when measuring the resistance between terminals.

3. When charging batteries.

Caution during assembly: To prevent damage to the throttle valve when reassembling the carburetor, re-install the carburetor with the throttle valve fully opened.

If the engine is difficult to start after the carburetor is installed, fully open the throttle valve by hand and then start the engine.

Economy Control Characteristics of an EF3000iSE/B

Economy Control Characteristics

Economy switch ON: 2800 rpm (with no load) Economy switch OFF: 3550 rpm

The engine will run at 2800 rpm with economy switch turned on, if the electrical consumption is below 1/4 of its rated output.

When a light and electric motor are connected to the generator at the same time, turning one of the devices on and off causes a change in voltage and could have an adverse effect on the other device.

Resistance 250Ω Terminal: F3-1, 3-5, 3-2, 3-4 500Ω Terminal: 1-5, 2-4 Throttle valve position: During assembly: Close During engine starting: Open

In these kinds of cases, first turn the economy switch off before use.

Throttle valve operation: ■ The throttle valve is fully opened when the engine is not running.

Economy Control Operation and Features Because output frequency of an inverter generator is unrelated to the engine speed, it is possible to use a wide range of engine speed.

■

When the engine is started with no load, the throttle valve will be set in an almost completely closed position as soon as the engine is started.

(When the economy switch is “ON,” it will be in a position to maintain 2800 rpm.)

■

The engine speed will be adjusted according to the requirements of the load on the system.

■

The throttle stops at the fully opened position when the engine is turned off in order to prepare for the next attempt to start the engine.

It also becomes possible to use low engine speed to meet a low electrical consumption.

The control unit commands the throttle motor built into the carburetor to control the throttle valve, which gives it the ability to continuously control the engine speed, which in turn makes the economy control system possible.

However, the economy control switch should be Economy Control Characteristics turned off in case of the following occasions:

In temperatures of 0° or below, the engine will automatically run at 3550 rpm for three minutes for warming up purposes, even when the economy control switch is turned ON.

1. When operating an electric motor, such as water pump, which requires a large starting current.

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e

Generator Information and Theory 3/14/03 4:20 PM

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The frequency variation of Yamaha inverter generators is less than 0.1%.

Continuous Running Time EF3000iSE is able to run for 20.5 hours with 1/4 load with fuel tank full, when economy control switch is on.

Voltage Variation

With rated load: 8.0 hours With 1/4 load: 20.5 Hours

The output voltage with no load is approximately 10% higher than rated voltage for a case of conventional synchronous type generators to achieve the rated voltage when full rated load is connected. Thus the voltage variation occurs due to the change in engine speed and the influence of the internal resistance.

Refer to Section 3 for model specific run times and rated load information.

However, adapting an inverter system, the voltage variation can be minimized, because the output voltage cannot be influenced directly from engine speed.

Frequency Variation Conventional synchronous generators have an engine speed with no load set at approximately 6% higher than rated engine speed (3600rpm for 60 Hz) to maintain rated frequency when full rated load is applied. This is the reason why no-load frequency is slightly higher than rated frequency.

The voltage variation of Yamaha inverter generators is smaller than 3%.

However, adapting an inverter system, which generates genuine sine wave electricity, the frequency variation of an inverter generator is not influenced by the engine speed. Therefore, an inverter generator provides constant AC output frequency even if the load changes which is equivalent quality to the commercial power supplies.

The waveform distortion rate of Yamaha inverter generators is smaller than 2.5%.

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Yamaha Generator Theory & Diagnostics Guide EF3000iSE new model guide

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Electronic Breaker

Instantaneous Frequency Fluctuation & Instantaneous Voltage Drop ■

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As opposed to the non-fuse breaker (NFB) used in synchronous type generators, Yamaha inverter generators use an electronic breaker circuit housed in the control unit. When output from the control unit exceeds a specific limit, output is automatically interrupted to protect the generator from damage.

Momentary frequency fluctuation: The frequency and voltage fluctuates momentarily when the load is altered if the engine cannot keep up with the load changes in the case of conventional synchronous generators.

The control unit is designed to continuously monitor the output current for overloads, and if the current overload continues longer than a specified time, output is interrupted.

In contrast the momentary frequency fluctuation of Yamaha inverter generators is as stable as the commercial power source with this new inverter system.

Characteristics of Electronic Breaker

When using induction motors or similar devices (such as underwater pumps) which require a large starting current with the generator, the current will not be interrupted even if the starting current exceeds several times the generator’s rated output.

Only when the large over current continues longer than a specified time, the control unit will interrupt the circuit, and in this way it resembles a mechanical NFB.

The frequency fluctuation rate of Yamaha inverter generators is less than 0.1%.

■

Momentary voltage drop: However, the momentary voltage drop occurs, when large electric load is turned on. This is caused by the fact that the electric energy stored in the condenser runs short momentarily until the engine speed picks up to sufficient engine speed to compensate the energy shortage in the condenser. The ratio of such momentary voltage drop and the rated voltage is defined as momentary voltage drop rate. The momentary voltage drop rate of Yamaha inverter generators is usually less than 20%. Naturally, the smaller the load capacity is applied, the smaller the momentary voltage drop becomes.

The engine must be stopped and power interrupted to the control unit in order for the system to reset after the electronic breaker has activated.

NOTE: If a device’s power switch is ON when it is connected the generator and the generator is subsequently started, the device may unexpectedly activate or start up as a result, creating a potentially dangerous situation.

In case of incandescent lamps, large amounts of current flow the moment it is switched on. The rush current may be as large as 10 times the rated current of the lamp. Therefore, when a large wattage incandescent lamp(s) are switched on, the momentary voltage drop is greater.

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Generator Information and Theory Control Panel

Output Indicator

Refer to Section 3 for model specific control panel diagrams.

When the generator is running normally and generating power, this indicator is lit green.

When using a device which requires a large starting current, the overload warning light (red) and output indicator (green) will temporarily light simultaneously. This operation is normal.

Indicators Overload Warning Lamp During power generation, 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 protect the generator and/or connected devices.

When the electronic breaker operates: The engine continues to run, but the control unit stops output

The output indicator (green) turns off The overload indicator (red) turns on

â–

When the overload warning light turns on: Stop the engine.

Verify the required load of the connected device, and reduce to the rated load of the generator if necessary. Verify whether or not there is a problem with a connected device. (A possible cause of excessive current drain.)

Check for foreign matter in the cooling air inlet and areas around the control unit which could block incoming air.

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After the connected device has started up, the overload warning light (red) will turn off, while the output indicator (green) will continue to be lit.

Oil Warning Lamp As with all Yamaha generators, the engine will shut off automatically when the oil level decreases to a specified level.

When this happens and the recoil starter is pulled, the engine will not start and the oil warning light will turn on.

To return the generator to normal output operation: Temporarily stopping the engine and re-starting automatically resets the system to its original state. (The system cannot be reset unless power to the control unit is interrupted by stopping the engine.)

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Yamaha Generator Theory & Diagnostics Guide Ventilation Be aware of the surroundings where generators are being used. Three (3) feet of clear space is necessary for safe operation. Adequate ventilation is also necessary, as the generator’s engine needs fresh air for the intake, Generator and the exhaust must be safely Rotor vented.

Refer to the Owner’s Manual for complete information.

Ass’y cooling Muffler Lubrication System

Cooling fan

air inlet

cooling air over generator and muffler The engine Flow unitsof of all Yamaha conventional and inverter generators use a splash type oiling system.

Cooling System

Control unit

The centrifugal fan equipped on the rotor performs forced air cooling of the system over the path listed below.

Each part of the system is therefore continuously kept at a stable operating temperature with only a single fan.

Cooling systems will vary from one model to another. The EF3000iSE is shown here as an example. Refer to the Owner’s or Service Manual for model Cooling specific information. air inlets

• Cooling air path • Control unit cover • Control unit Intake box Fan case Cooling fan • Alternator • Engine (cylinder) EF3000iSE new model model guide guide EF3000iSE new Flow of cooling air over generator and muffler • Muffler

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Controller Cooling air inlets

Cooling air inlets

Generator Generator cooling RotorAss’y Ass’y cooling Rotor airinlet inlet air Coolingfan fan Cooling

Muffler Muffler

Battery Muffler

Generator cooling air inlet Generator fan

Recoil starter

Flow of of cooling cooling air air over over generator generator and and muffler muffler Flow

Overall flow of cooling air Controlunit unit Control

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Generator Storage To prepare a Yamaha generator for storage follow these basic procedures: • 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 unit should be covered and stored in a cool dry place.

•

Refer to the Owner’s or Service Manual for complete storage information.

Cooling Cooling airinlets inlets air

Intakebox box Intake

Coolingfan fan Cooling

Fancase case Fan

Flow of of cooling cooling air air over over generator generator and and muffler muffler Flow

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Generator Information and Theory Y Y Y

DC 12V Output

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ON START

!5

1 Main coil !6 2 Sub coil M @5 @3 3 DC coil 4 DC rectifier 5 Control unit u u 6 AC pilot light y 7 AC receptacle 8 Ground (Earth) terminal t r o 9 Economy control switch 0 Overload indicator light !0 i q DC receptacle !1 w DC protector (breaker) e Engine switch !2 r Oil warning light t Speed limiter assenbly y Oil level gauge !9 u T.C.I. unit !4 !3 i Spark plug @4 @2 DC 12V circuit is entirely separated from!5AC circuit. o T.C.I. magneto Stepping motor Economy control switch must be turned off while charging apabattery, as the engine speed 3550 rpm is required DC-DC converter to generate rated DC-output. s Rectifier !6 d Battery M @5 consumption of both the AC and the DC output should not Rectifier The total electric exceed the total rated output of f Starter relay @3 the generator, which is 2800 Va, when both output are used together. g Starter motor

Y Y Y L G R

Y

Y L

G/Y

R/W

R

q

B/W

L

i

!1 !2 O G/Y R R/W

O

W

W

!7

B/W

B/W B/W O O

O

!0 G/Y

W

B B/W

R

G/Y

B/W

O

B

G

u

o Y

BW

G Y R L O

Br

y

O G/Y R R/W

O

W

R

B

R B

B/W

L

R

W

R R

Y

Y

Y

L

B/W

L

R/W G/Y R O

B B/W

B/W B R

Br R

Br

OFF

ON START

O

G/Y

R/W G/Y

R

L

R R G/Y R/W

Rectifier (for DC output)

(–)

(+)

(~)

Polarity of rectifier 7VU-87105-00

Rectifier

1-11

(~)

(~)

(–)

1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a s d f g

Main c Sub c DC co DC re Contro AC pil AC re Groun Econo Overlo DC re DC pr Engin Oil wa Speed Oil lev T.C.I. Spark T.C.I. Stepp DC-DC Rectif Batter Starte Starte

Yamaha Generator Theory & Diagnostics Guide Battery Charging ■

Conditions of use of the DC power supply

■

Charging a 12V battery Do not use for other than charging a 12V battery.

First-aid procedures: If your skin or clothes come in contact with the electrolyte, wash them with a large amount of water immediately. If it enters your eyes, wash with a large amount of water and consult the doctor immediately.

WARNING

The time taken to charge a battery depends on how the battery is discharged. Charging is complete 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 discharged will be almost fully charged in about 3 hours. Be sure to check the level of the electrolyte.

Do not take energy from the battery nor run the starter when the battery is being charged. This could cause a large current to flow through the generator coil, burning it.

■

Precautions for charging the battery

WARNING The battery will produce a flammable gas. The wrong handling might result in explosion or serious injuries. Be sure to observe the following when charging a battery.

1. Keep fire and electric sparks away. Explosion might happen.

2. Secure a good ventilation where the battery is charged. Otherwise, explosion might happen.

3. Be very careful to handle the electrolyte (diluted sulfuric acid). It will burn anything, so keep it away from your eyes, skin and clothes.

4. Before charging a battery, remove all cords connected to the battery, doing it first from the negative side. When reconnecting, do the positive side first. If you do it incorrectly, a short-circuit could result.

1-12

•

When handling a battery, keep good ventilation and keep electric sparks, like from short-circuit, away. Also, keep fire away.

Explosion might happen because a flammable gas occurs from the battery.

•

The battery electrolyte is diluted sulfuric acid. If it comes in contact with your eyes or skin, the affected part will be burnt. If it should happen, wash the part with a large amount of water for at least 15 minutes and consult the doctor immediately.

Generator Information and Theory EF2800i AC-CDI The Yamaha EF2800i Inverter generator is the only generator in the Yamaha line-up to use an AC-CDI. A CDI unit which uses AC power to charge the condenser is referred to as an AC-CDI. Taking the low voltage power generated by the charge coil (which is wound around a single stator core in the multi-polar alternator), a voltage booster circuit boosts the voltage in the CDI in order to charge the condenser. In a typical CDI system, voltage of approximately 200~400 volts is generated by the charge coil.

The advantages are the charge coil can be made both lighter and smaller. Also a heavier wire can be used for the charge coil to increase its reliability.

An overrun limiter is incorporated into the EF2800i’s AC-CDI unit.

The ignition spark is regulated to prevent engine speed overrun when the engine speed exceeds 4500 rpm.

A new oil warning system was designed to match the new CDI system, while maintaining the same function of the conventional oil warning system.

1-13

Yamaha Generator Theory & Diagnostics Guide The EF1000iS Exclusive to the EF1000iS, the double-coil system is a unique design that adds to the main coil a second coil specifically for running at lower rpm. Increasing the number of coils in this second low-speed coil enables it to generate optimum electricity when the engine is running at lower rpm. When the engine rpm increases, however, these extra coils become unwanted resistance that reduced generating efficiency. Thus, a system has been adopted that automatically selects the right coil in relation to the engine rpm; the low speed coil becomes the main generating coil at low rpm and the main coil from middle to high rpm. This is a Yamaha-exclusive technology that might be called a dual-stage system to accommodate low and middle range rpm. The result is a generating system that can provide optimum electricity supply that is stable even at low rpm and thus run with less noise and better fuel economy.

EF1000iS

1-14

Generator Information and Theory Power Boost Technology EF3000iSEB is equipped with a DC-DC converter, which supplies supplemental electric current to the inverter control unit to boost up the generator output by an additional 500 watts for maximum 10 seconds. This feature Control Unit is exclusive on the EF3000iSEB.

Control Unit

DC-DC Converter (Power Boost Technology) The DC-DC converter is an electrical device to step up DC voltage. The EF3000iSEB DC-DC converter 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 current exceeds 20 amps and the voltage at the condenser inside the control unit drops down to below 190 volts.

The power source is a 12-V battery installed in the generator to operate the starter motor. DC-DC converter works for maximum 10 seconds, only when a DC-DC converter large amount of starting current is needed and increases maximum output of generator from 3000 VA to 3200 VA temporarily.

DC-DC converter

Specifications of DC-DC converter 1. DC input 12V Battery 2. DC output DC190V 3. Rated DC current 2.53 A 1-15

– 14 –

– 14 –

Yamaha Generator & Diagnostics Guide 3/14/03 4:20 PM Theory Page 15

EF3000iSE new model guide

Overload Indicator Lamp: The DC-DC converter is turned on automatically, when the generator output exceeds over 180% of its rated load to boost generator output to assist the starting current of the load, such as an air conditioner.

When the DC-DC converter is turned on automatically, the generator is obviously overloaded, thus the overload indicator lamp blinks quickly with 0.5-second interval for 10 seconds. And the lamp blinks slowly with 1-second interval for 3 minutes and 50 seconds. During this period, the DC-DC converter is prevented from rebooting to prevent the battery from over-discharged.

Designation of LED Indicators:

⎫ ⎪ ⎪ ⎪ ⎪ ⎬ ⎪ ⎪ ⎪ ⎪ ⎭

DC-DC converter unit is equipped with two indicator lamps (LED) on the unit. When the DC-DC converter is activated automatically, indicator lamps are lit or blink to designate the state of the system. The designations of indicator lamps are listed in the table below.

⎫ ⎪ ⎪ ⎪ ⎪ ⎬ ⎪ ⎪ ⎪ ⎪ ⎭

Green LED Red LED Designation ON OFF Standby mode Blink OFF Output (for 10 seconds maximum) OFF Blink For 10 seconds after shutdown OFF ON Alarm mode Red LED Designation OFF Standby mode OFF Output (for 10 seconds maximum) Blink For 10 seconds after shutdown ON Alarm mode

Green LED ON Blink OFF OFF

NOTE: The red LED turns ON and interrupts DC-DC converter output automatically to protect the component, when any of the abnormal operating conditions is detected, and returns to normal operation automatically as soon as the abnormality is recovered.

Abnormal conditions are: 1. Too high temperature in the component 2. Too low battery voltage, below 9.5V 3. Too high battery voltage, over 18V

1-16

Generator Information and Theory TCI Ignition System TCI ignition system is equipped with a speed limiter function.

Speed limiter: 4500 rpm

Oil Warning System The oil-warning unit is built in the speed limiter unit.

The oil-warning switch is installed in the crankcase.

When the engine oil level drops below the specified level, the ignition system is grounded and the engine will be automatically stopped. This 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.

The ignition coil and TCI unit is a single built-in unit, while the speed limiter unit is a separate component installed in the control box.

1-17

guide

Yamaha Generator Theory & Diagnostics Guide EF3000iSE new model guide

3/14/03 4:20 PM

Auto-decompression System

Page 23

Muffler Cleaning

model guide 3/14/03 Page All Yamaha EF3000iSE generators new are equipped with an auto- 4:201. PMTurn the 23 engine switch to the “STOP” position to decompression system to facilitate engine starting stop the engine. operation.

2. Loosen the bolt ① and remove the muffler cap While the engine is stationary or running at very low and muffler screen.

3/14/03speed, 4:20 PM 18 a pinPage provided in the camshaft is projected above the basic circle of exhaust cam lobe.

The pin, consequently, pushes the valve lifter causing the exhaust valve to stay open, thus compression pressure is released.

When the engine speed becomes faster, the decompression weight, which holds the pin in the position, is thrown out and the pin moves back, thus the engine can be started as the exhaust valve functions normally.

1

1 3. Remove the carbon deposits on the muffler cap ②, the muffler screen ③ and the spark arrester 2 ④ using a wire brush.

3 42 3 4

4. Install the muffler screen ③, the muffler cap ② and the spark arrester ④.

1-18

Generator Information and Theory

Battery Initial Charging Procedure

1. Cases in which Charging of a New Battery is Required (Initial Charging)

Although the Sealed Motorcycle MF Battery can be used after it is filled with electrolyte, it may not be able to start a motor in cases like those indicated in the table below. In such cases, perform initial charging before using the battery. Furthermore, initial charging is not required if the terminal voltage (*1) ten minutes after filling with electrolyte is not less than 12.5V.

2. Initial Charging Procedure

Although the procedure for initial charging of the Sealed Motorcycle MF Battery is based on the charging procedure indicated on the top of the battery, it is recommended to determine the duration of initial charging based on the terminal voltage.

YT4L-BS

NOTE: a. Terminal Voltage

Use a digital voltmeter (or voltmeter of class 1 accuracy or better) to measure battery terminal voltage. Continue to measure terminal voltage in the same manner. b. Standard Current Charging Time

Set the standard current to the current value indicated as the standard charging current on the top of the battery.

If the terminal 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 current flows after five minutes. Charging a battery that has become excessively discharged to less than a battery terminal voltage of 11.5V charging may not be possible at the normal charging voltage (16~17V) due to high internal resistance. In such cases, initially increase the charging voltage (maximum 25V), and then charge for about 5 minutes. (The battery must be replaced if there is no change in the voltmeter reading (A) after 5 minutes.) Since excessively high current will flow once the current begins to flow, always make sure to adjust the voltage of the charger so as not to exceed the standard current. This initial charging procedure can be performed automatically by using the Yuasa MF Battery Charger (such as model PS1512).

3. Assessing Battery Performance After Initial Charging

Assessment of battery performance following charging of the Sealed Motorcycle MF Battery should be made by measuring battery terminal voltage after allowing the battery to stand for about 30 minutes following completion of charging.

NOTE: Use of the Yuasa Model BM-310 Battery Tester lets you make a more accurate assessment of battery performance.

1-19

Yamaha Generator Theory & Diagnostics Guide No Fuse Breaker (NFB) Sometimes called a Non Fuse Breaker, this device acts like a fuse to interrupt power in the event of a sudden spike or surge in current. Unlike a fuse, however, the NFB can be reset.

WARNING Electrocution, severe personal injury or death can occur: Do not connect any generator to any building’s electrical system unless an isolation switch has been installed by a licensed electrician. Refer to the Generator Owner's Manual.

Electronic Breaker An electronic circuit breaker automatically cuts off the current when the output voltage exceeds the maximum capacity.

Property damage can occur: Do not connect any generator to any building's electrical system unless an isolation switch has been installed by a licensed electrician. Refer to the Generator Owner's Manual.

Smart-Throttle Because output frequency of an Inverter Generator is unrelated to engine rpm it becomes possible to utilize a wide range of engine rpm. This feature helps quiet running by choosing the minimum engine rpm necessary for the actual electrical load.

A double coil system such as on the EF1000iS makes possible a higher output even at a low rpm setting. Smart Throttle ONLY applies to inverter models that have an electronic throttle servo motor to control engine speed.

Take It Step-By-Step Follow these steps when determining your energy needs: 1. Identify the wattage requirements for the tools and appliances that you want to power. The power requirements for the tool or appliance are found on its identification plate or in the Owner's Manual. If the power requirement is given in amps, multiply the amps times volts to derive the required watts.

Amps x Volts = Watts

Economy Control (also called Economy Idle) Conventional generators, and in some cases inverter generators use economy control / idle. This function causes the unit to idle down when a load is not present.

Ground Fault Interruption (GFI) Shuts down the power when a fault to ground is detected. A device that interrupts the power flowing through a GFI receptacle when a proper ground/ earth ground is not present or a short were to take place - to prevent electrocution

2. Add up the required watts of all the tools and appliances you expect to operate simultaneously.

3. The total watts derived in step 2 equals the size Yamaha generator you need. These three simple steps will “size” a generator. However, you must keep in mind that devices with electric motors require at least 2-3 times their running wattage for start-up power. This multiplier varies with the age, type, and condition of the electric motor. A good “rule of thumb” to use for this is Horse Power multiplied by 932 usually equals a motor’s starting wattage (HP x 932 = SW).

Right Sizing and Power Management: Determining Your Consumer Series Customer’s Energy Needs When selling a generator, it is important to select one that is capable of meeting the energy requirements of the customer. Match the rated output of the generator to the maximum anticipated power demand.

The chart on the next page lets you immediately add up all of the appliances you will most likely utilize:

This section will assist in estimating the power requirements, so the purchase will satisfy the needs.

Make a list of the appliances and devices or tools that you expect to operate, as well as the approximate power requirements for each device.

After making the list, estimate the highest demand on the generator under the “worstcase” conditions.

With this figure, determine the appropriate model Yamaha generator for your particular needs.

1-20

Generator Information and Theory CONSUMER GENERATOR WORKSHEET Additional Running Starting Wattage Wattage Requirements* Requirements Totals

Additional Running Starting Wattage Wattage Requirements* Requirements Totals HEATING/COOLING:

APPLIANCES

Furnace Fan, gas or fuel oil furnace

Lights- Wattage

Actual:

VCR

50

0

500

Heating Pad

65

0

1/8 horsepower

300

1/6 horsepower

500

750

Radio

100

0

1/4 horsepower

600

1000

100

0

2/5 horsepower

700

1400

Television - Black & White

3/5 horsepower

875

2350

Television - Color

300

0

Central Air Conditioner 10,000 BTU

1500

2200

20,000 BTU

2500

3300

24,000 BTU

3800

4950

32,000 BTU

5000

6500

40,000 BTU

6000

6700

HEATING/COOLING:

SUB-TOTAL:

KITCHEN Refrigerator, Average

600

2200

Dehumidifier

400

0

Electric Blanket

400

0

Garage Door Opener 1/4HP

550

1100

Garage Door Opener 1/3HP

725

1400

Well Pump - 1/3 hp

750

1400

Well Pump - 1/2 hp

1000

2100

Sump Pump - 1/3 hp

800

1300

Sump Pump - 1/2 hp

1050

2150

800

0

1100

0

Dish Washer Cool Dry

700

1400

Vacuum Cleaner Standard

Dish Washer Hot Dry

1450

1400

Vacuum Cleaner Deluxe

Clothes Dryer - Gas

700

1800

Clothes Dryer Electric

5750

1800

Microwave Oven, 1000W

1500

1650

Washing Machine

750

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

APPLIANCES

*Running wattage values are for estimation only.

SUB-TOTAL:

BATHROOM Hair Dryer 1500 watt

1500

0

Iron

1200

0

BATHROOM

SUB-TOTAL:

SUBTOTAL:

1-21

Yamaha Generator Theory & Diagnostics Guide

EF4000DE

EF5200DE

EF6600DE

EF12000DE

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

Radio 100

•

•

•

•

•

•

•

•

•

•

EF3000ISE

•

EF2800I

EF2600

VCR 50 75 Watt Light Bulb (Single) 75

APPLICATION / WATTS*

EF1000IS

EF2400IS

EF3000ISEB

CONSUMER APPLICATION TABLE

Television (B&W) 100

•

•

•

•

•

•

•

•

•

•

Window Fan 250

•

•

•

•

•

•

•

•

•

•

Blender 300

•

•

•

•

•

•

•

•

•

•

3/4" Drill 350

•

•

•

•

•

•

•

•

•

•

Television (Color) 350

•

•

•

•

•

•

•

•

•

•

RV W/NO Appliances On 400~600

•

•

•

•

•

•

•

•

•

•

RV Refrigerator 600

•

•

•

•

•

•

•

•

•

•

650 Watt Microwave Oven 1000

•

•

•

•

•

•

•

•

•

•

Washing 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 1200

•

•

•

•

•

•

•

•

•

•

Space Heater 1300

•

•

•

•

•

•

•

•

•

•

RV Water Heater 1500

•

•

•

•

•

•

•

•

•

•

1000 Watt Microwave 1500

•

•

•

•

•

•

•

•

•

•

1500 Watt Blow Dryer 1600

•

•

•

•

•

•

•

•

•

•

Electric Range (One Element) 1500

•

•

•

•

•

•

•

•

•

•

4-Slice Toaster 1650

•

•

•

•

•

•

•

•

•

•

7 1/4" Circular Saw 2000

•

•

•

•

•

•

•

•

•

•

Disc Grinder 2000

•

•

•

•

•

•

•

•

•

•

Air Compressor 2000

•

•

•

•

•

•

•

•

•

•

Air Conditioner (10,000 BTU) 2500**

•

•

•

•

•

•

Refrigerator / Freezer 250

•

•

•

•

•

•

Water Heater 3000

•

•

•

•

•

•

•

•

•

Well Pump 4500

*Running wattage values are for estimation only. **Capable of running most 13,500 btu air conditioners.

1-22

Generator Information and Theory Determining Your Industrial Series Customer’s Energy Needs

This chart provides information on the wattage needs of common commercial devices and tools:

industrial generator worksheet

INDUSTRIAL APPLICATION TABLE

Watts

YG4000D

YG5200D

YG6600D

YG6600DE

Premium Series

YG2800i

Inverter Series

3/4" Drill

350

•

•

•

•

•

3-1/4" Planer

500

•

•

•

•

•

Reciprocating Saw

500

•

•

•

•

•

Airless Sprayer 1/3 HP

600

•

•

•

•

•

1/2" Drill

700

•

•

•

•

•

APPLICATION*

Electric Weed Trimmer

1000

•

•

•

•

•

Rotary Hammer

1000

•

•

•

•

•

Router

1000

•

•

•

•

•

Belt Sander

1000

•

•

•

•

•

Running Wattage Requirements*

Additional Starting Wattage Requirements Totals

COMMERCIAL PRODUCTS: 1/4" Drill

300

300

Jigsaw

300

300

Electric Weed Trimmer

500

500

Router

1000

1000

Belt Sander

1000

1000

Disc Sander

1200

1200

Chain Saw

1200

1200

Worm Drive Saw

1560

3100

12" Concrete Cutter

1800

3600

1500

6-1/2" Planer

1200

•

•

•

•

•

7 1/4" Circular Saw

Disc Sander

1200

•

•

•

•

•

Disc Grinder

2000

4000

Electric Chain Saw

1200

•

•

•

•

•

2000

4000

Space Heater

1300

•

•

•

•

•

Air Compressor, Average

Demolition Hammer

1500

•

•

•

•

•

10" 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 Conditioner 13,500 BTU

1200

•

•

Air Conditioner 10,000 BTU

2500

Air Conditioner 15,000 BTU

•

•

•

•

•

•

•

•

•

•

•

COMMERCIAL PRODUCTS:

SUB-TOTAL: GRAND TOTAL

*Running wattage values are for estimation only.

1-23

Yamaha Generator Theory & Diagnostics Guide CONSUMER DECIBEL LEVEL COMPARISONS

INDUSTRIAL DECIBEL LEVEL COMPARISONS

GENERAL ESTIMATES OF WORK-RELATED NOISES

GENERAL ESTIMATES OF WORK-RELATED NOISES

120

120 Ambulance Siren

120

120 Ambulance Siren 119 Pneumatic Drill

114

114 Hammer Drill

114

114 Hammer Drill

105

105 Airless Paint Sprayer

EF12000DE

96

96

90

90

80

80

70

70

108 Continuous Miner

105

Tractor

Lawn Mower

80 dBA

EF5200D, EF6600DE

73.5 dBA

EF4000DE, EF2600A

69 dBA

EF2600 EF2800i EF2400iS

67 dBA 60~67 dBA 53~58 dBA

60

EF3000iSE, EF3000iSEB

51~57 dBA

50

50

EF1000iS

47~57 dBA

35

35

25

25

Ringing Telephone

Vacuum Cleaner

YG5200D, YG6600D, YG6600DE

73.5 dBA

105 Airless Paint Sprayer 98

Hand Drill

96

96

Tractor

90

90

Lawn Mower

80

80

Ringing Telephone

70

Vacuum Cleaner 70

Normal Speech 60

60

60

Normal Speech

50

50

Business Office

Soft Whisper

35

35

Soft Whisper

Bedroom at Night

25

25

Bedroom at Night

Business Office

1-24

YG000D

69 dBA

YG2800i

60~69 dBA

Generator Information and Theory

Model Name Clarification YG/EF Yamaha generators have various model names that represent the characteristics of the respective models as follows:

Consumer Generators

E

F

6600

AC Max. output

(kVA) at 60Hz

F: Four stroke DA: Air cooled diesel engine DL: Liquid cooled diesel engine

G: Generators*

DE B: D: E: I: S:

Boost Technology Dual 120/240V AC output Electric Starter Inverter Technology Soundproof Type

E: Engine generator Y: Yamaha* *NOTE: The letters YG are always used together to designate Yamaha Industrial 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 identify one model from another. The MIY is used to identify the year that a certain unit was either first introduced to the US Market, or received a significant technological update. The MIY does not necessarily coincide with the actual year of manufacture. In certain cases it may be necessary to explain this to a customer who is buying a new generator from your dealership. This explanation will create a higher level of customer satisfaction by preventing a customer from believing that they are buying a used/or non-current generator.

1-25

Yamaha Generator Theory & Diagnostics Guide Extension Cord Guidelines

Resistor and Non-Resistor Spark Plugs Resistor type spark plugs are used in all Yamaha generators. Do not use non-resistor type spark plugs. Refer the Owner’s Manual or Service Manual for complete information.

A proper extension cord must always be used. If a cord is not heavy enough for the load it must carry, it could burn or there could be a severe reduction in power available at the end of the cord.

Neutral Ground and Floating Ground (Open Ground – False Ground+) Neutral Ground (also called “neutral bond”) means earth ground and neutral are bonded together (wired together). This creates less chance of electrocution by providing two paths for electricity to travel in the event of a short.

The following chart shows the minimum extension cord wire size for the amount of the expected load.

Note that the wire size increases with the length of the cord as the anticipated load increases. Lightgauge cords can be easily damaged. Practical considerations suggest that small-size cords (20 gauge or smaller) be avoided.

Floating Ground means that earth ground and neutral are NOT bonded together. All Yamaha Inverters use a “floating ground” grounding method.

EXTENSION CORD GAUGE *LOAD (AMPERES)

Devices that require a Neutral Ground (bonded neutral) will not work correctly when plugged into a floating ground generator - this is because the device can not locate an earth ground presence.

MINIMUM GAUGE (AWG) 0 ~ 50 Feet

50 ~ 100 Feet

100 ~ 150 Feet

2

22

20

18

3

22

18

16

4

20

16

16

5

18

16

14

6

18

16

14

8

16

14

12

10

16

12

12

12

16

12

10

14

14

12

10

16

14

10

10

18

14

10

8

20

12

10

8

22

12

10

8

25

12

10

8

30

10

8

6

35

10

8

6

40

8

6

4

50

6

4

2

60

4

2

2

Ground Fault Circuit Interrupter (GFCI) A GFCI protected outlet interrupts power delivery when a fault or short to ground is detected to prevent electrocution. It is a device that interrupts the power flowing through a GFCI receptacle when a proper ground is not present or if/when a short occurs. All Yamaha Industrial series generators (YG models) are equipped with GFCI protected outlets.

1-26

1-27 7CB

7RH-14101-21

•

YG4000D/YG5200D

EF6600A

7CC

EF4000DE/ EF5200DE/ EF6600DE 7WY

7CC

7CC

•

EF6600DE

7CB

7CB

7CB

7UW-14101-00

7CT-E4101-70

7CU-E4101-40

7CU-E4101-00

7CT-E4101-20

7WW

EF6000/EF6600

7UV-14101-00

7RG-14101-20

7CC

7WX

EF4600A

EF6600

7WV

EF4500/EF5200

7VW-14101-30

7VW-14101-20

7CU-E4101-31

7CP-E4101-10

7CP-E4101-00

7VU-14101-20

7VU-14101-11

7CN-E4101-A0

7CN-E4101-10

7NJ-14101-10

7CF-E4101-11

7RU-14101-31

7VW

7CH

7DF

7CA

7CF-E4101-01

7NH-14101-10

7CG-14101-00

EF6000/EF6600

7VW

7XF

EF4000

•

EF4500iSE

7CH

EF4000

•

EF3000iSEJ

7WL

7VU

EF3000iSE

7VU

•

7CA

EF2800iJ

•

EF2800i/YG2800i

EF2600J

7CA

7CF

EF2400iSJ

EF2300/EF2600/ EF2600FW

7CF

EF2400iS 7NJ

7NH

EF1600

•

7CG

EF1000iS

EF2600/EF2600A

7VV

EF1000iS 7CJ

7TA-14101-10 7VV-14101-03

7FL-14101-00 7XD

7TA

EF1000A / EF1000B

Model

Sudco Mikuni Carburetor Model Number

EF1000

Carb Tier 3

USA/CAN

USA

USA

USA

USA

USA

USA

USA/CAN

USA

USA/CAN

USA/CAN

USA

USA

USA

USA

USA

USA

OTH/JPN/USA

USA/CAN

USA

USA

USA/CAN

USA

USA

USA/CAN

USA/CAN

N102/221

N100/606

N100/606

N100/606

N100/606

N100/606

N100/606

N102/221

N102/221

N100/606

N100/606

N100/606

N100/606

N100/606

N100/606

N100/606

N100/606

N100/606

N100/606

N100/606

N100/606

N100/606

N100/606

N100/606

N102/221

N102/221

Sudco Mikuni Carburetor Type

105.0

115.0

115.0

98.8

98.8

98.8

98.8

100.0

98.8

86.3

86.3

115.0

86.3

101.3

91.3

88.8

86.3

91.3

91.3

91.3

86.3

75.0

58.8

57.5

56.3

57.5

Sea Level Main Jet Number

100.0

107.5

107.5

98.8

98.8

98.8

98.8

97.5

98.8

82.5

82.5

106.3

80.0

96.3

85.0

85.0

80.0

90.0

90.0

85.0

82.5

73.8

55.0

53.8

56.3

57.5

2000 Meters / 6561 Ft Main Jet Number

98.8

101.3

101.3

97.5

97.5

97.5

97.5

96.3

98.8

81.3

81.3

101.3

78.8

93.8

83.8

81.3

78.8

87.5

87.5

83.3

80.0

72.5

52.5

51.3

55.0

56.3

3000 Meters / 9842 Ft Main Jet Number

97.5

97.5

97.5

96.3

98.8

80.0

80.0

82.5

82.5

80.0

87.5

72.5

55.0

56.3

3600 Meters / 11,881 Ft. Main Jet Number

96.3

98.8

98.8

96.3

96.3

96.3

96.3

95.0

98.8

78.8

78.8

97.5

77.5

90.0

82.5

78.8

77.5

86.3

86.3

82.5

77.5

71.3

50.0

50.0

53.8

55.0

4000 Meters / 13,123 Ft. Main Jet Number

High Altitude Jetting Rejetting Yamaha generators for high-altitude applications should be done by an authorized Yamaha dealer or other qualified technician. Several factors affect jetting decisions, including: altitude, average temperature, and barometric pressure. The following chart describes general high altitude jetting settings. In North America, aftermarket jetting parts are available from Sudco Mikuni, phone (323) 728-5407, www.sudco.com.

Generator Information and Theory

Yamaha Generator Theory & Diagnostics Guide Special Diagnostic Tools Utilizing the correct diagnostic tool for the job is critical to our main goal, Customer Satisfaction.

Having the 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 Conventional generators.

1. Load Bank Tester / Generator Test Set

The load bank main use is to duplicate problems, and verify the generator works properly after a repair. It can apply an adjustable load between 1-50amps. Many generators are capable of producing large amounts of power, so it is necessary to use a tool to create a large, measurable load to simulate any output issues. Heat guns, drills, fans, and grinders are not good diagnostic tools as there is no way to measure and maintain a large load. As a dealer technician it is difficult to determine exactly how much load you are applying when not using a load bank tester. The load bank can also be used as a sales tool to determine if a generator has enough capacity to meet the customer’s needs.

Generator Test (Load Bank) Uses Typically, the only way to test the generator if you don’t have a load bank, is to plug some type of tool into it and turn it on. If it operates the tool, you assume that it’s making electricity and must be fixed.

This is not necessarily true.

Just because one appliance works, it does not guarantee that the unit will work for the customer. If the customer gets the unit home or to a construction site and immediately finds out that it still does not work for his application, your Customer Satisfaction level with this customer will be in serious jeopardy.

This can be easily avoided by the use of a generator test set. The generator test set will make it possible to select the amount of current used by a particular customer under real world conditions.

You can even select the amount of current for a given generators rated output and let it run for awhile at that power load. If it passes that test you are practically guaranteed that it will work for your customer.

Most generator test sets also feature a frequency meter to enable you to make that adjustment.

Another excellent use for the generator test set, which very often becomes a major problem in customer satisfaction, is for the proper selection of a generator for a given application.

If there is any question as to the amount of current that a certain appliance or a combination of tools will require, all the guess work can be eliminated by plugging the generator test set into an external power source with high amperage capabilities and then plugging the appliance or tools into the generator test set.

The generator test set’s amp meter will not only tell you the required amount of current for normal operation, but will also tell you what the start up current requirements are.

Start up current requirements are an often overlooked step in proper generator selection and should always be taken into consideration.

You will need to take the start up amperage plus a cushion, to determine the generator size. The cushion will allow for the possibility of future requirement increases.

The customer will be much happier with your dealership if you were able to foresee his future needs. Especially when his needs do change and he would have had to purchase another generator, if you had not made him aware of that possibility.

2. Hertz (Hz) Meter

The hertz meter is used to properly set the frequency. U.S. applications will be 60 Hz adjusted by increasing or decreasing engine rpm.

3. Pulse Tachometer

A tachometer is used to set the rpm on all gasoline powered models.

1-28

Generator Information and Theory 4. AmWatt™ Meter

AmWatt™ Hand-held Appliance Load Tester by Reliance controls. This 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 the load a device draws (under 15 amps or 1800 watts).

2. Rotor assembly puller

You can remove the rotor assembly using the flywheel magnet puller and M6 bolts (3).

90890-01351 FLYWHEEL MAGNET PULLER

90890-01355 BOLT, FLYWHEEL MAGNET PULLER

5. Multi-Meter & Analog Meter

Resistance tests should be done with a digital meter. An analog ohm meter will not read a 10 or 20 percent variance from 1 ohm or less. Be certain to “zero” an analog meter before use.

Also, use clips to connect the leads to the wires being tested. holding both test wires to the leads with your hands will distort the test results. An analog meter is required to test condensers on conventional generators.

3. Engine tachometer

Use of the PET-1000 or PET-2000DX engine tachometer made by Oihama Kogyo Co., Ltd. is recommended.

ADDITIONAL SPECIAL TOOLS 1. Rotor assembly holder

A tool available in markets will serve.

Note that the reading may not be right if the position of the engine tachometer is wrong.

Keep it away from the engine.

90793-80009 ENGINE TACHOMETER (PET-1000)

HOZAN C-349 (drum remover) overall length: 360mm

90793-80032 ENGINE TACHOMETER (PET-2000DX)

1-29

Generator Diagnostics CONVENTIONAL GENERATOR DIAGNOSTICS Introduction All conventional Yamaha generators, with the exception to the EDL6500S, are brushless self-exciting type generators. There are two methods of brushless self-exciting generators.

The first method is by using residual magnetism within the rotor as a source of excitation. These are models below 4,000 watts and are referred to as non-AVR type models.

The second method is through the use of a permanent magnet within the Exciter Field Coil. These are models that are rated at 4,000 watts or higher and are usually referred to as AVR or Automatic Voltage Regulator models, which we will cover in detail later.

The EDL6500S uses the same basic theory to generate electricity, with the exception to it’s method of self-excitation. This is done by supplying DC current from the AVR circuit board to the rotor, through brushes that ride on a set of slip rings on the rotor.

2-1

Yamaha Generator Theory & Diagnostics Guide Theory for Non-AVR Type Generators The diagnostic procedures for all non-AVR models are the same. It will be necessary, however, to refer to each models service manual for the exact specification of voltage and resistance readings.

These models depend on residual magnetism within the rotor to begin 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-coil.

That AC voltage is then rectified into DC voltage by a diode known as the rotor rectifier.

The DC voltage then turns the rotor into a large magnet.

This process is repeated until the engine is at full speed and the generator reaches it’s rated output.

The non-AVR type generator relies on a steady engine speed to maintain a constant voltage.

2-2

Generator Diagnostics Troubleshooting Procedures for Non-AVR Type Generators Occasionally, the rotor may lose it’s residual magnetism and make it impossible for the generator to begin the cycle of electricity. This can be caused by prolonged periods of non-use or from the shock of being dropped. If the problem description was something like, “The unit has been unused for quite sometime and it worked fine the last time it was used, but now has no output” or “The unit was working fine until it was dropped while being loaded onto the truck, and now it has no output. This could be the cause.

This repair is actually quite simple. First verify the problem by starting the engine, then turn the AC protector to the “ON” position.

With your meter set to a high enough AC scale to accept 200 volts, insert the meter leads into the receptacle, polarity is not important.

If there is little or no output, remove the generator end cap and locate the sub-coils 2 pin connector with the two green wires.

NOTE: The sub-coil wires on most conventional models are green but check the manual of the model you are working on for exact colors and connectors.

With the generator running, apply a 12 volt DC power source to the two green wires, again, polarity is not important, for about 5 seconds.

REMAGNETIZING ROTOR

Recheck for output at the receptacle. If power is now restored, turn the generator off for a minute or two.

Restart the generator and again check for voltage output.

G G

If voltage is restored, you should still make any minor adjustments such as frequency, which is directly related to engine RPM and is adjusted with the governor, as well as check the operation of the generator by using a generator test set.

If the voltage was not restored or the unit came in for another problem such as low voltage, further troubleshooting will be required.

Because voltage output is directly related to engine speed, a low voltage problem may be caused by incorrect engine RPM. So, check that first.

Using a tachometer, set the engine RPM to the RPM specified in the Service Manual. In most cases it will be 3,750 RPM, without a load. Then recheck the voltage at the receptacle. If the voltage is correct, the problem is fixed.

2-3

Yamaha Generator Theory & Diagnostics Guide If not, continue to the next step.

With the meter set for 200 volts AC and the generator end cap removed, check for voltage between the brown and the red wire.

If the voltage is 120, then the problem is in the control box, such as the AC protector or the receptacle itself, or with the wiring between the generator and the control box.

Check all wiring and test the AC protector and the receptacle for continuity.

SUB-COIL RESISTANCE TEST

If the voltage is below specification, then the problem is within the generator unit itself.

Start by disconnecting the sub and main coil leads and set your meter to the specified range 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.

MAIN COIL RESISTANCE TEST

Even if the stator passes both of these tests, there are still two important tests to perform before we can eliminate the stator as the problem.

Those two tests are a “Short to Ground” and “Shorted Together” test.

To better understand these tests, we need to know the construction of the two types of coils.

The first type is a single lead coil. This is where an insulated wire is wrapped around an iron core, with one end of the wire attached to the core.

SINGLE LEAD COIL RESISTANCE TEST

A resistance test on this type of coil is taken between the unattached end of the wire and the core. A short to ground test does not apply here.

2-4

Generator Diagnostics The other type is a dual lead coil which is used in generator applications. It has an insulated wire wrapped around an iron core with neither end attached to the core. Because the wire is insulated there is no physical contact between the wire and the core. A normal resistance test is performed by attaching the meter leads to each end of the coil leads.

DUAL LEAD COIL RESISTANCE TEST

DUAL LEAD COIL SHORT TO GROUND TEST

In this case a short to ground test does apply. The short to ground test is performed by connecting one lead of the meter to either coil lead and the other meter lead to the core. With the meter on the highest ohm scale possible, it should read an open 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 shorted together test comes in.

DOUBLE COIL SHORTED TOGETHER TEST

When one meter lead is attached to any wire from one of the coils and the other meter lead is attached to any wire from the other coil, an open circuit should exist.

Any resistance reading indicates the two coils are shorted together.

MAIN COIL SHORT TO GROUND TEST

Test the main and sub-coils for a short to ground.

With the meter on the highest resistance setting and one meter lead on either the Red or the Brown wire from the main coil and the other lead on the core, there should be an open circuit.

2-5

Yamaha Generator Theory & Diagnostics Guide Then from either Green wire from the sub-coil to the core. Any resistance reading from either test, indicates that the stator is shorted to ground and must be replaced.

SUB-COIL SHORT TO GROUND TEST

Next test for them being shorted together. With the meter on the highest resistance setting and one lead on either the Brown or the Red wire from the main coil and the other lead on either of the Green wires from the sub-coil, check for an open circuit. Any resistance reading indicates that the two coils are shorted together and the stator must be replaced.

SUB-COIL TO MAIN COIL SHORTED TOGETHER TEST

If the stator passes all of the above tests, it can be eliminated from being the cause of the problem.

For the next test it will be necessary to remove the front of the control panel and disconnect the condenser. To avoid electrical shock, do not touch the terminals of the condenser. Short the terminals together with an insulated screwdriver to discharge it.

Using your analog meter on the RX1k ohm scale, connect the meter leads to the condenser. The meter should swing to one side and then quickly return. If it does not, switch the meter leads on the terminals.

CONDENSER TEST

If the meter still does not move or swings to one side but does not return, then the condenser must be replaced.

The rotor assembly will need to be removed in order to perform the final two test. Refer to the Service Manual for the model you are working on, for the correct procedure.

2-6

Generator Diagnostics

Use extreme care when handling the stator and rotor. DO NOT set them on their windings.

Damage will occur.

CHECKING ROTOR RECTIFIER IN ONE DIRECTION

Once the rotor has been removed, unsolder the diode or diodes, depending on the model, using caution not to damage it by overheating.

Set your meter to the diode checker scale or the highest ohm scale if your meter does not have a diode checker. Test across the diode and note the reading.

Switch the meter leads and test again, noting the reading. You should have continuity, or a resistance reading, in one direction, but not in the other direction.

CHECKING ROTOR RECTIFIER IN OPPOSITE DIRECTION

The diode is bad if you have continuity in both directions, or an open circuit in both directions.

The last step is testing the Main Field Coil or better known as the rotor windings.

The resistance test must be done with the diode(s) still unsoldered. Connect the meter to both ends of the rotor windings, using care not to touch both leads with your hands, as this will cause the meter to read your body’s resistance.

ROTOR RESISTANCE TEST

2-7

Yamaha Generator Theory & Diagnostics Guide Then test for a short to ground. Connect one meter lead to one end of the rotor winding and the other end to the core of the rotor. There should be an open circuit on a good rotor.

ROTOR SHORT TO GROUND TEST

One of these tests should reveal the faulty component.

Theory for AVR Type Generators As mentioned earlier, the generation of electricity 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 generated by the Exciter Armature Coil, one of the three sections that make up the rotor, spinning inside of the Exciter Field Coil’s permanent magnet.

This AC voltage is then fully rectified into DC voltage by four diodes mounted on the rotor. These diodes are referred to as Rotor Rectifiers and are the second of the three rotor sections.

2-8

Generator Diagnostics

That DC current then flows through the Main Field Coil, the last section of the rotor, and turns it into a north and a south pole magnet.

The magnet spinning inside the sub-coil will then produce about 4-6 volts AC in the sub-coil.

That AC current is fully rectified by diodes within the AVR circuit board. This increased DC current then flows back through the Exciter Field Coil, Exciter Armature Coil, Main Field Coil and Sub-Coil, which causes their voltage to rise and in turn causes the voltage in the Main Coil to rise to the rated output.

There are only three extra components in 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 fluctuation in the engine RPM. This is achieved by two voltage detecting taps on the main stator coil that are connected to the AVR board.

When the voltage in the main stator coil reaches the rated output, but is about to exceed it because of increasing engine RPM, the AVR board detects that voltage increase and reduces the amount of output voltage from itself to the exciter field coil.

The voltage reduction to the exciter field coil in turn reduces it’s output voltage through the rotor and thus reduces the voltage from the main coil. This process is continuously repeated to maintain a constant voltage.

2-9

Yamaha Generator Theory & Diagnostics Guide Troubleshooting Procedures for AVR Type Generators The troubleshooting procedure starts out exactly the same way as with the non-AVR type.

First check the engine speed, especially if the problem is slightly low voltage. Adjust if out of specification.

MAIN COIL RESISTANCE TEST Br R

Turn on the AC protector and check the voltage output at the receptacle. Continue on to the next step if it is out of specification.

Check the voltage at the generator unit. Remember, if the voltage is OK there, but 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 resistance test, short to ground test and the shorted together test on all of the coils.

SUB-COIL RESISTANCE TEST

Be sure to reference the proper Service Manual for the model you are working on for specifications and wiring color codes.

Disconnect all of the coils at the connectors.

Start with the resistance test on the Main Coil, the sub-coil resistance test,

EXCITER FIELD COIL RESISTANCE TEST

and the Exciter Field Coil resistance test, which is the two pin connector with the black and white wires.

2-10

Generator Diagnostics

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.

SUB-COIL SHORT TO GROUND TEST

EXCITER FIELD COIL SHORT TO GROUND TEST

MAIN COIL SHORT TO GROUND TEST Br R

2-11

Yamaha Generator Theory & Diagnostics Guide And last, check for the Sub and Main Coils for being shorted together.

MAIN AND SUB-COIL SHORT TOGETHER TEST

CONDENSER TEST

If the problem was not found in any of these areas, proceed to the condenser test using the analog meter.

Check to see if the needle swings and then returns, replace it if it does not.

Some models are equipped with a voltage adjuster that should be tested per the Service Manual’s specifications.

It is a variable resistor that should show a smooth rise in resistance as the knob is turned from one end of it’s scale to the other.

If the voltage adjuster shows an open circuit throughout the scale or at any one point in the scale, it should be replaced.

It should also be replaced if the resistance is out of specification.

Next, remove the rotor assembly to test the rotor rectifiers, the exciter armature coil and the main field coil.

ROTOR RECTIFIER TEST

Unsolder the coils from the rotor rectifiers, noting where the wires go for reference when it comes time to reattach them, and test the diodes in the same manner as on the non-AVR model. There should be continuity in one direction but not the other.

2-12

Generator Diagnostics And last, test the Exciter Armature Coil resistance and short to ground.

EXCITER ARMATURE COIL RESISTANCE TEST

SHORT TO GROUND TEST

Then the Main Field Coil resistance and short to ground.

MAIN FIELD COIL RESISTANCE TEST

If the problem was not with any of these components, it will then be necessary to replace the AVR circuit board.

Correctly following these procedures, should have revealed the problem in one of these areas.

SHORT TO GROUND TEST

2-13

Yamaha Generator Theory & Diagnostics Guide Theory for AVR Type Generators with Brushes This type of generator unit is used in Yamaha’s EDL6500S diesel generator. It is still a self-exciting type generator, but uses a brush and slip ring set up to complete the loop that turns the rotor into a large magnet.

BRUSH TYPE AVR GENERATOR

Generation of electricity begins when a small permanent magnet inside the rotor begins to spin inside the sub-coil. That AC voltage is then sent to the AVR circuit board, where it is full wave rectified into DC voltage.

The DC voltage is then sent from the AVR board to the main field coil in the rotor, through the brushes and magnetizes the rotor. This causes the main coil in the stator to suddenly increase voltage to the rated output.

Troubleshooting Procedures for AVR Type with Brushes The troubleshooting procedure is very similar to the other types. The big difference with this type is that it is not necessary to remove the rotor from the generator assembly to test it. This is because there are no diodes soldered inside and the windings can be tested through the slip rings Once again we’ll quickly go through the steps that we’ve already covered and detail the new ones a little more closely.

First verify the problem. If the voltage is a little low, make sure that the engine RPM is correct. On this model, the RPM should be set at 3,250.

This is be done by using the special photoelectric tachometer that is designed for diesel engines.

Follow the directions with the tachometer for proper usage and this models Service Manual for proper adjustment procedures.

If there is still little or no voltage from the receptacle, then check for 120 volts AC between the red and white wires and 120 volts AC between the brown and blue wires on the generator unit.

If the voltage is good, check the wiring and the control box. If not, proceed to testing the generator.

Disconnect all of the wires from the generator unit, in preparation for the tests.

2-14

Generator Diagnostics

Check for resistance in the main coil, this model is 0.33 ohms, +10%, between the red and white wires and the same between the brown and blue wires.

Testing Procedures for Models EquipPed with DC Circuitry As mentioned with the EDL6500S, some other Yamaha models also have DC 12 volt capabilities.

Then check the resistance in the sub-coil for 0.97 ohms, +10%, between the light green/red and the green wires in the 4 pin connector.

Models such as the early model non-inverter EF1000, produce this voltage by tapping off of the main coil and using a full wave rectifier to convert the AC voltage to DC.

There is also a battery charge coil inside the stator assembly. If the complaint is everything works good, except the battery keeps going dead. Check the resistance between the two blue/white wires that are in the 2 pin connector for 0.1 ohms, +10%.

On models like this, if the problem is only with the DC portion of generator, it probably has a bad rectifier.

If everything checks out OK there, test all three of those coils for a short to ground. And if it still checks out, test for them being shorted together. Be sure to check between the main coil and the sub coil, the main coil and the battery charge coil and the sub coil and the battery charge coil.

Test the rectifier according to the specific model’s Service Manual.

Because the DC circuit uses the main coil to provide it’s voltage, a problem with the AC side will more than likely result in a problem with the DC side as well.

If the problem was not found in the stator assembly, then we’ll move on to the rotor.

As with the other coils, test for normal resistance, short to ground and shorted to the sub-coil. If it is part of the main coil it cannot be shorted to the main coil, but be sure to check the Service Manual for the model you are working on.

Remove the brush assembly and inspect them for wear. The standard length is 12.5mm and the wear limit is 9mm. Replace them and retest the generator if they’re below the wear limit. If they check OK, then we’ll test the rotor windings resistance while the brushes are off.

Place the meter leads on the two slip rings that the brushes ride on. The reading should be 55.1 ohms, +10%.

If that is OK, test it for being shorted to ground by placing one meter lead on one of the slip 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 last test will be the AVR circuit board. First reinstall the brush assembly, but do not connect the wire leads. Disconnect the emergency relay unit and start the engine.

Apply 12 volts DC to the brush terminals with the “+” to “+” terminal and the “-” to “-” terminal.

Check the sub coil voltage between the light green/ red and the green wires for 53 volts AC. If the voltage is correct, then the AVR board is bad and should be replaced.

As with the AVR and Non-AVR models, one of these tests should reveal the problem.

2-15

Yamaha Generator Theory & Diagnostics Guide

2-16

Generator Diagnostics

2-17

Yamaha Generator Theory & Diagnostics Guide TROUBLESHOOTING YAMAHA INVERTER GENERATORS This guide has troubleshooting flow charts and information to help the Service Department technician correctly diagnose electrical output and engine running problems. Many diagnostic procedures are the same for all Yamaha inverter generators, and differences among generators are noted. However, this guide is meant as a familiarization tool and should not be substituted for the appropriate service manual. Test specifications vary from model to model, so these numbers are in Section 3 of this book.

Determining 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 with the engine.

It is important we remember that the generator depends on the engines ability to maintain a specific speed, for it to provide a constant current output.

Be sure you have not overlooked the possibility that the reason the generator does not have the proper output, is because the engine has lost it’s ability to keep up with the generator’s needs.

A typical scenario for this may be that the generator’s output is OK with no load or a light load, but the output decreases or becomes erratic as the load increases. Providing that given load would not normally exceed the rated output.

2-18

Inverter Generator Diagnostics

2-19

Yamaha Generator Theory & Diagnostics Guide

2-20

Inverter Generator ELEC Diagnostics IGNITION SYSTEM

*

2 1

2) Secondary coil resistance 9 Connect the pocket tester (Ω × 1k) to the secondary terminal.

Tester (+) lead → High-tension cord 1 Tester (–) lead → Ground terminal 2 Secondary coil resistance: Refer11.5 to Service Section for°C Specifications kΩ ±Data 20% at 20 (68 °F)

MEETS SPECIFICATION

OUT OF SPECIFICATION

Replace the ignition coil.

5. Air gap 9 Measure the thickness between the magnet rotor and ignition coil.

Air gap: Refer to Service Data Section 0.5 ± 0.1 mm (0.02 for ± Specifications 0.004 in)

MEETS SPECIFICATION

OUT OF SPECIFICATION

Adjust the air gap.

6. Engine switch 9 Disconnect the engine switch coupler in the control box.

9 Connect the pocket tester (Ω × 1k) to the engine switch terminal.

1

Tester (+) lead → Black/white terminal 1 Tester (–) lead → Black terminal 2

2

Switch “ON” → Continuity Switch “STOP” → No continuity CONTINUITY

NO CONTINUITY

Replace the engine switch,

* 2-21 5-6

B/W B

7VV10-05

02.10.7 1:41 PM

Page 7

Yamaha Generator Theory & Diagnostics Guide IGNITION SYSTEM ELEC *

å

7. Oil level switch 9 Remove the oil level switch from the bottom of the crankcase.

Refer models Service Manual CAMSHAFT for removal Refertoto “CRANKSHAFT2, procedure.

AND ROCKER ARM” in CHAPTER 3.

9 Connect the pocket tester to the oil level switch for continuity.

∫

2

2

1

1

Tester (+) lead → Blue lead 1 Tester (–) lead → Ground 2 å Continuity → Correct ∫ No continuity → Correct CONTINUITY

NO CONTINUITY

Replace the oil level switch.

8. Wire harness 9 Check the terminal of the connector for contamination, rust, or disconnection.

GOOD

NO GOOD

Correct or replace the connector.

Replace the speed limiter.

GOOD Replace the TCI unit.

2-22

5-7

ELEC Diagnostics GENERATOR SYSTEM Inverter Generator GENERATOR SYSTEM TROUBLESHOOTING CHART WEAK OR NO ACOR CURRENT: DUAL AC COIL (EF1000iS) WEAK NO AC CURRENT Start the engine.

Check the overload warning light.

Check the overload warning light.

DOES NOT TURN ON

TURNS ON

TURNS ON

DOES NOT TURN ON

Start the engine.

Check the pilot light.

DOES NOT TURN ON

TURNS ON

Check the pilot light.

Rated engine speed inspection.

9 Operate the engine with no load.

9 Set the economy switch to “OFF”.

Check the throttle control system.

5,000 r/min

Refer to “THROTTLE CONTROL SYSTEM” in

GOOD

OUT OF SPECIFICATION

CHAPTER 6.

Magnetic force is weak.

AC coil 1 AC voltage inspection 9 Connect Brown-Green (R-S), Green-Brown (S-T),

Replace the magneto rotor.

and Brown-Brown (R-T) leads.

9 Start the engine, then measure the voltage. (Tester range: AC300V)

AC coil 1 resistance inspection 9 Stop the engine.

9 Measure the resistance between Brown-Green

R

(R-S), Green-Brown (S-T), and Brown-Brown (R-T)

AC coil 1

leads. (Tester range: Ω × 1) S

T

R

W Br Br W Or G Br W W Br Br W

R

AC coil 1

AC coil 2

S

T

W Br Or G W Br

S

T

R AC coil 2

AC coil 1 AC voltage: Refer to Service Data Section for Specifications 130 ~ 260 V at 20 °C (68 °F) GOOD

T

TOO LOW DOES NOT GENERATE

S

AC coil 1 resistance: Refer to Service Data Section for Specifications 0.47 Ω ± 20% at 20 °C (68 °F)

*

SPECIFICATION

Replace the AC coil 1.

5-8

2-23

OUT OF SPECIFICATION

Yamaha Generator Theory & Diagnostics Guide ELEC GENERATOR SYSTEM

* Magnetic force is weak.

AC coil 2 AC voltage inspection 9 Connect White-Orange (R-S), Orange-White (S-T),

Replace the magneto rotor.

and White-White (R-T) leads.

9 Start the engine, then measure the voltage. (Tester range: AC120V)

AC coil 2 resistance inspection 9 Stop the engine.

9 Measure the resistance between White-Orange

R

(R-S), Orange-White (S-T), and White-White (R-T)

AC coil 1

leads. (Tester range: Ω × 1) S

T

W Br Br W Or G Br W W Br Br W

R

R AC coil 1

AC coil 2

T

S

T

S

W Br Or G W Br

R AC coil 2

AC coil 2 AC voltage:

Refer13.5 to Service DataVSection ~ 23.0 at 20 for °CSpecifications (68 °F)

GOOD

TOO LOW

S

T

DOES NOT GENERATE

AC coil 2 resistance: 0.17 Ω ± 20% at 20 °C (68 °F)

Refer to Service Data Section for Specifications

SPECIFICATION

Economy switch continuity inspection 9 Switch “ON” → Continuity 9 Switch “OFF” → No Continuity CONTINUITY

Replace the AC coil 2.

NO CONTINUITY

Replace the control unit.

2-24

5-9

OUT OF SPECIFICATION

ELEC

Inverter Generator Diagnostics

GENERATOR SYSTEM GENERATOR SYSTEM TROUBLESHOOTING CHART WEAK OR NO AC CURRENT: AC COIL MODELS WEAK OR NOSINGLE AC CURRENT Start the engine.

Check the overload warning light.

Check the overload warning light.

DOES NOT LIGHT ON

LIGHT ON

LIGHT ON

DOES NOT LIGHT ON

Start the engine.

Check the pilot light.

DOES NOT LIGHT ON

LIGHT ON

Check the pilot light.

No load engine speed inspection.

9 Operate the engine with no load.

2,600 r/min

Check the throttle control system.

GOOD

OUT OF SPECIFICATION

Refer to “THROTTLE CONTROL SYSTEM” in CHAPTER 6.

Magnetic force is weak.

Main coil AC voltage inspection 9 Start the engine.

Replace the magneto rotor.

9 Connect the pocket tester to the White leads.

9 Measure the voltage. (Tester range: AC 300 V)

Main coil resistance measurement 9 Stop the engine.

9 Measure the resistance between the White leads.

(Tester range: Ω × 1) W WW

Y Y Y

Main coil AC voltage: Refer to Service Section for(68 Specifications 175 ~ 225Data V at 20 °C °F)

GOOD

W

TOO LOW

W W

DOES NOT GENERATE

Main coil resistance: Refer to Service Data Section Ω ± 20% at 20 for °CSpecifications (68 °F) 1.22

*

SPECIFICATION

OUT OF SPECIFICATION

Replace the stator assembly.

2-25

5-8

Yamaha Generator Theory GENERATOR & Diagnostics Guide ELEC SYSTEM * Magnetic force is weak.

Sub coil AC voltage inspection 9 Connect the White leads of the sub coil 1.

9 Start the engine, then measure the voltage. (Tester

Replace the magneto rotor.

range: AC120V)

1

Sub coil resistance inspection

W W Or L W W Or L

9 Stop the engine.

9 Measure the resistance between the-White Orange leads. (Tester range: Ω × 1)

Sub coil AC voltage: 13.0 ~ 18.0 V at 20 °C (68 °F)

Refer to Service Data Section for Specifications

GOOD

TOO LOW DOES NOT GENERATE

1

W W W W

Sub coil resistance: Refer to Service Data Section Ω ± 20% at 20 for °CSpecifications (68 °F) 0.19

SPECIFICATION

Replace the control unit.

OUT OF SPECIFICATION

Replace the stator coil assembly.

2-26 5-9

ELECDiagnostics GENERATOR SYSTEM Inverter Generator TROUBLESHOOTING CHART WEAK OR NO DC CURRENT Rated engine speed inspection.

9 Operate the engine with no load.

9 Set the economy switch to “OFF”.

• Set running 5,000 r/min rpm per Service Manual.

GOOD

Check the throttle control system.

Refer to “THROTTLE CONTROL SYSTEM” in

model service manual.

CHAPTER 6.

OUT OF SPECIFICATION

Check the DC circuit breaker.

GOOD

DISCONNECTED

Replace the DC circuit breaker.

Magnetic force is weak.

DC coil DC voltage inspection 9 Connect Blue leads.

Replace the magneto rotor.

9 Start the engine, then measure the voltage. (Tester range: DC 20V)

DC coil resistance inspection 9 Stop the engine.

9 Measure the resistance between Blue leads.

(Tester range: Ω × 1)

L L

L L

DC coil DC voltage: 13.5 ~ 23.0 V at 20 °C (68 °F)

Refer to Service Data Section for Specifications

GOOD

L L

TOO LOW DOES NOT GENERATE

DC coil resistance: Refer to Service Data Section 0.07 Ω ± 20% at 20 for °CSpecifications (68 °F) SPECIFICATION

Replace the rectifier.

Replace the DC coil.

5-10 2-27

OUT OF SPECIFICATION

Yamaha Generator Theory & Diagnostics Guide TRBL ENGINE ENGINE TROUBLESHOOTING TROUBLE SHOOTING ENGINE

ENGINE DOES NOT START Check that the oil warn-

Check connections between oil warning unit

Replace oil

ing light turns ON by

and oil level switch.

warning

GOOD

pulling the starter rope.

LIGHT ON

NO GOOD

light, oil

DOSE NOT

warning

TURN ON

unit, or oil level switch.

Check engine oil level.

SUFFI-

INSUFFI-

CIENT

CIENT

Add. Add. Check if fuel is deteriorated.

Check fuel level.

SUFFI-

INSUFFI-

CIENT

CIENT

GOOD

NO GOOD

Replace.

Check fuel cock lever position.

“ON”

Set to

“OFF”

“ON”.

Check if fuel flows to fuel cock.

GOOD

Clean or NO GOOD

Check if fuel is deteriorated.

GOOD

Remove

spark

replace NO GOOD

plug,

Clean or

attach it to spark plug cap, and then ground the spark plug to check for

fuel pump.

9 Check spark plug for dirt and check spark plug gap.

replace fuel cock

9 Check for voltage leakage due to faulty con-

spark.

GOOD

WEAK OR

SPARK

NO SPARK

nection or broken insulation of the high tension cord.

9 Check TCI unit connector for corrosion or faulty connection.

9 Check the ignition system. Refer to “IGNI-

*

TION SYSTEM” in CHAPTER 5.

GOOD

NO GOOD

Clean or replace.

Install a substitute TCI unit to check spark conditions.

Replace GOOD

NO GOOD

the fuel TCI unit.

2-28 6-1

TRBL

Inverter Generator Diagnostics

ENGINE

* Check

carburetor

for

clogged passages or fuel overflow.

NOT GOOD

GOOD

Measure

valve

Replace.

clear-

ance.

GOOD

OUT OF

Adjust.

SPECIFICATION

Check

compression

using

compression

1 2 3

gauge.

OUT OF SPECIFICATION

4

GOOD

Check valve face and valve seat for wear.

GOOD

Resurface

WEAR

or replace.

Check if the marks on the

crankshaft

and

camshaft are aligned.

GOOD

Correct or

NO GOOD

6

replace.

7

Check if there is seizure or wear on the piston, piston ring, or cylinder.

GOOD

5

SEIZURE

Rebore or

OR WEAR

replace.

Check the condition of the throttle control system. Refer to “THROTTLE CONTROL SYS-

TEM” TEM”. in Model’s Service Manual.

2-29

6-2

7VV10-06

02.10.4 10:41 AM

Page 3

Yamaha Generator Theory & Diagnostics Guide ENGINE TRBL ENGINE STARTS BUT STALLS Check fuel level.

SUFFI-

INSUFFI-

CIENT

CIENT

Add.

Check if fuel cock is clogged.

NO GOOD

GOOD

Clean.

Check if fuel hose is clogged.

NO GOOD

GOOD

9 Check retaining

if

Clean.

9 Tighten the

carburetor nuts

carburetor

are

bolts

loose.

securely.

9 Check if there is air suction due to a dam-

9Replace

aged carburetor joint or

carburetor

gasket.

joint or gasket with a

NO GOOD

GOOD

new one.

Measure

valve

clear-

ance.

GOOD

OUT OF

Adjust.

SPECIFICATION

Check

compression

using

compression

gauge.

GOOD

OUT OF SPECIFICATION

Check piston, piston ring and cylinder.

GOOD

NO GOOD

Replace.

Check air gap.

GOOD

Replace.

NO GOOD

Check the condition of the throttle control system. Refer to “THROTTLE CONTROL SYS-

TEM” TEM”. in Model’s Service Manual.

2-30

6-3

7VV10-06

02.10.4 10:41 AM

Page 4

Inverter Generator Diagnostics

ENGINE

TRBL

ENGINE SPEED DOES NOT INCREASE Check if the electric equipment consumes too much wattage for this generator.

GOOD

TOO MUCH

Use a generator with a larger capacity.

NO GOOD

Clean.

Check air filter element for dirt.

GOOD

Check spark plug for dirt and check spark plug gap.

GOOD

NO GOOD

Clean or adjust.

NO GOOD

Adjust.

Check valve clearance.

GOOD

Check if main passages such as, the main jet, in the carburetor are clogged.

GOOD

Disassemble or clean.

NO GOOD

Check for air suction due to a damaged throttle shaft seal, carburetor joint, or gasket.

GOOD

Disassemble or replace.

NO GOOD

Check compression using compression gauge.

GOOD

Decarbonize combustion chamber if

TOO HIGH

there are carbon deposits.

TOO LOW

Check valve face and valve seat for wear.

GOOD

NO GOOD

Resurface or replace.

Check if the marks on the crankshaft and camshaft are aligned.

GOOD

Correct.

NO GOOD

Check if there is seizure or wear on piston, piston ring, or cylinder.

GOOD

Rebore or replace.

SEIZURE OR WEAR

Check the the condition condition of of the the throttle throttle control control system. system.

Check Refer CONTROL SYSTEM” in Referto to “THROTTLE “THROTTLE CONTROL SYSTEM”.

Model Service Manual.

2-31

6-4

Yamaha Generator Theory & Diagnostics Guide TRBL ENGINE ENGINE SPEED IS UNEVEN Check fuel level.

SUFFICIENT

Add.

INSUFFICIENT

Check if fuel is deteriorated.

GOOD

NO GOOD

Replace fuel.

NO GOOD

Replace.

NO GOOD

Clean.

NO GOOD

Replace.

Check if fuel tank cap is clogged.

GOOD Check if fuel cock is clogged.

GOOD Check fuel pump operation.

GOOD

Check spark plug for dirt and check spark plug gap.

GOOD

Clean, adjust or replace.

NO GOOD

Check valve clearance.

GOOD

OUT OF SPECIFICATION

Adjust.

While the engine is operating, pull the choke knob approximately 1/3 to 1/2 way out, and then check the

Resurface or replace.

engine operating condition.

STABLE

UNSTABLE

Check for air suction due to a damaged throttle shaft seal, carburetor joint, or gasket.

GOOD

Disassemble or replace.

NO GOOD

Check if slow or main passages such as, the pilot jet and main jet, in carburetor are clogged.

GOOD

Disassemble or clean.

NO GOOD

Check valve face and valve seat for wear.

GOOD

Resurface or replace.

NO GOOD

Check if there is seizure or wear on piston, piston ring, or cylinder.

GOOD

Rebore or replace.

SEIZURE OR WEAR

Check Check the the condition condition of of the the throttle throttle control control system. system.

Refer CONTROL SYSTEM” in Refer to to “THROTTLE “THROTTLE CONTROL SYSTEM”.

Model Service Manual.

2-32 6-5

Inverter Generator Diagnostics

the Model’s Service Manual.

Resistance 250Ω

500Ω

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

Throttle valve position:

During assembly:

During engine starting:

Close Open

2-33

Yamaha Generator Theory & Diagnostics Guide THROTTLE CONTROL SYSTEM TRBL With no load, engine speed does not increase when economy control switch is set to “OFF”.

With no load, engine speed does not decrease when economy control switch is set to “ON”.

With load, engine speed does not increase when economy control switch is set to “ON”.

Check AC output.

GOOD

Refer to “GENERATOR SYSTEM” in

NO GOOD

the Model’s5. Service Manual.

CHAPTER

Rotate the shaft of the throttle control motor.

GOOD

NO GOOD

Replace the throttle control motor.

NO GOOD

Replace the economy switch.

Check economy switch.

GOOD

Check the connections of the wire harness connectors and couplers, and the wires for an open circuit or short circuit.

GOOD

NO GOOD

Correct or replace.

Replace the control motor.

2-34 6-7

Inverter Generator ELEC Diagnostics CHARGING SYSTEM –

+

CHARGING SYSTEM TROUBLESHOOTING CHART THE BATTERY IS NOT CHARGED Inspection steps: 1. Fuse 2. Battery voltage 3. Charging voltage

4. Charging coil resistance 5. Rectifier 6. Wire harness (charging system circuit)

NOTE: • Remove the following part(s) before troubleshooting.

1) Battery bracket 2) Fuel tank • Use the following special tool(s) for troubleshooting.

Inductive self-powered tachometer: YU-8036-B Engine tachometer: 90890-03113 (90793-80009, 90793-80032)

Pocket tester: YU-03112-C, 90890-03112

1. Fuse • Remove the fuse.

• Connect the pocket tester (Ω × 1) to the fuse.

• Check the fuse for continuity.

NO CONTINUITY

CONTINUITY

Replace the fuse.

2. Battery voltage • Connect the pocket tester (DC 20 V) to the battery terminals.

• Measure battery voltage.

Tester positive lead → positive terminal Tester negative lead → negative terminal OUT OF SPECIFICATION

Battery voltage:

Refer to Service Data Section for Specification 12.8 V or more

GOOD • Clean the battery terminals.

• Recharge or replace the battery.

*

2-35

4-15

Yamaha Generator Theory &CHARGING Diagnostics Guide ELEC SYSTEM

* 3.

• • •

–

+

C0NTINUITY È

Charging voltage Start the engine.

3,800 r/min (no load) Measure the charging voltage.

1 2

Tester positive lead → positive terminal 1 Tester negative lead → negative terminal 2

SWL4120J

È EF3000iSE É EF3000iSEB

É

1 2

SWL4120

MEETS SPECIFICATION

Charging voltage: Refer 12 to~ Service 16 V Data Section for Specification OUT OF SPECIFICATION

Properly connect the charging system.

4. Charging coil resistance • Disconnect the charging coil connector.

• Connect the pocket tester (Ω × 1) to the charging coil.

1

Tester positive lead → White terminal 1 Tester negative lead → Ground 2

2 SWL4130J

Charging coil resistance: White-Ground: Refer0.35 to Service Ω ± Data 20%Section at 20for °CSpecification (68 °F)

OUT OF SPECIFICATION

GOOD

Replace the charging coil.

* 2-36

4-16

– + Inverter Generator Diagnostics

CHARGING SYSTEM

*

ELEC

C0NTINUITY

5. Rectifier • Disconnect the rectifier connector.

• Connect the pocket tester (Ω × 1) to the rectifier.

• Check the rectifier for continuity.

Normal Tester positive lead → White 1 Continuity Tester negative lead → Red 2 Tester positive lead → Red 1 No ContinuTester negative lead → ity White 2

1 NO CONTINUITY

Replace the rectifier.

2 SWL4135

CONTINUITY DISCONNECTED

6. Wire harness (charging system) Check the terminal of the connector for contamination or rust, and the connector for proper connection.

Correct or replace the connector.

2-37 4-17

Yamaha Generator Theory & STARTING Diagnostics Guide ELEC ELECTRIC SYSTEM ELECTRIC STARTING STARTING SYSTEM ELETRIC SYSTEM TROUBLESHOOTING CHART THE STARTER MOTOR DOES NOT OPERATE Inspection steps: 1. Fuse 2. Battery voltage

3. Starter motor 4. Starter relay

NOTE: 9 Remove the following part(s) before troubleshooting.

1) Control panel 9 Use the following special tool(s) for troubleshooting.

Pocket tester: YU-03112-C, 90890-03112

Inductive self-powered tachometer: YU-8036-B Engine tachometer: 90890-03113 (90793-80009, 90793-80032)

1. Fuse

NO CONTINUITY

9 Remove the fuse.

9 Connect the pocket tester (Ω × 1) to the fuse.

9 Check the fuse for continuity.

Replace the fuse.

CONTINUITY 2. Battery voltage 9 Connect the pocket tester (DC 20 V) to the battery terminals.

9 Measure battery voltage.

OUT OF SPECIFICATION

Tester positive lead → positive terminal Tester negative lead → negative terminal Battery voltage: Refer to Service Data Section for Specification 12.8 V or more

9 Clean the battery terminals.

9 Recharge or replace the battery.

*

2-38 5-15

Inverter Generator ELECDiagnostics ELECTRIC STARTING SYSTEM

* 3. Starter motor 9 Connect the jumper lead to the starter relay terminals on the battery side and the starter motor side.

DOES NOT MOVE Check the battery.

DOES NOT MOVE MOVES Repair and/or charge the battery.

Repair and/or replace the starter motor.

w 9 A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead, otherwise the jumper lead may burn.

9 This check is likely to produce sparks, so be sure that no flammable gas or fluid is in the vicinity.

1 Jumper lead

9 Check the starter motor operation.

MOVES 4. Starter relay 9 Disconnect the engine switch connector.

9 Connect the jumper lead to the starter relay connector terminals.

NO CONTINUITY 1 Jumper lead

9 Check the starter motor operation.

Replace the starter relay.

MOVES Replace the engine switch.

2-39 5-16

Yamaha Generator Theory & Diagnostics Guide

Resistance 250Ί

500Ί

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

Throttle valve position:

During assembly:

During engine starting:

Close Open

2-40

TRBL

Inverter Generator Diagnostics

CHOKE CONTROL SYSTEM

* Measure the coil resistance between Blue/Yellow-

Checking steps:

Black/Red of the thermo sensor.

1. Conect the pocket tester(Ω × 1k) to

(tester range:Ω × 1k)

the thermo sensor.

2. Soak the thermo sensor into the coolant until the 1/3 a of the hexagon Ω×1k

as shown.

3. Slowly heat the coolant,and then let it cool to the specified temperature indicated.

a

4. Check the thermo sensor for at the temperatures indicated.

Coil resistance: Refer to Service DatakΩ Section for °C Specification at 30 (86 °F) 2.647-3.021

Coil resistance: Refer to Service Data Section for Specification °C (248°F) 0.1859-0.1988 kΩ at 120 SPECIFICATION

OUT OF SPECIFICATION

Replace the thermo sensor.

Check the connections of the wire harness connectors and couplers, and the wires for an open circuit or short circuit.

GOOD

NO GOOD

Correct or replace.

Replace the control unit.

2-41

6-8

Current Model Specifications and Wiring Diagrams CURRENT MODEL SPECIFICATIONS AND WIRING DIAGRAMS This section contains relevant service data for all current Yamaha conventional and inverter generators. The information is arranged for both the consumer and industrial 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 specifications to do the maintenance or repair without going from one section of the service manual to the next.

However, this section is not designed to replace the appropriate Service Manual.

Also included in this section are component location drawings, wiring diagrams, and circuit diagrams.

3-1

7VV10-05

02.10.9 8:36 AM

Page 1

Yamaha Generator Theory & Diagnostics Guide CONSUMER SERIES GENERATORS ELECTRICAL COMPONENTS

ELEC

INVERTER GENERATOR EF1000iS ELECTRICAL ELECTRICAL COMPONENTS 5 4 3

6

2 1

q

0

9

1 2 3 4 5 6 7 8 9 0 q w e r t y

Control unit assembly Speed limiter Overload warning light (Red) Pilot light (Green) Oil warning light (Red) Generator assembly Engine switch Economy switch DC circuit breaker AC receptacle (7.5 A × 2) DC receptacle (12 V-8 A) Spark plug cap High-tension cable Ignition coil Throttle control motor Rectifier

7

8

t w e

y

1 r 6

3-2

5-1

3-3

g

4

T

R

3

2

T

1

f

R

G Y R L O

S

S

G

G

W

W

5-2

d

Y

Or

Br

Br

L

s

R

CIRCUIT DIAGRAM

O

L L

a

L L

W Br Br W Or G Br W W Br Br W

p

Br

L

Br Br

5

W

o

L

W W

B

W

W Br W Br W Br

G Y R L O

B

L

B/W

6

B

L

B/W

B B/W

Br Br R R

R Y

i

B/W

B

W

7

Y

L B/W O Y B

e

w

q

R

R

O

B/W

B R

Br

Br

B/W

Y

r

W

W

0

9

R

Br

B

B/W

Y

B/W B

8

y

t

G/Y

B

G/Y

u

AC coil 1 (AC) AC coil 2 (AC) DC charge coil Generator assembly Rectifier Control unit assembly Pilot light (Green) AC receptacle (7.5A × 2) Economy switch Overload warning light (Red) DC circuit breaker DC receptacle (12V-8A) Speed limiter TCI unit Engine switch Oil warning light (Red) Ground terminal Control box Ground terminal Oil level switch Magneto rotor Ignition coil Spark plug Throttle control motor Engine assembly COLOR CODE B ........Black Br .......brown G........Green L.........Blue Or.......Orange R ........Red W .......White Y ........Yellow B/W....Black/White G/Y ....Green/Yellow

1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a s d f g

Current Model Specifications and Wiring Diagram – EF1000iS

CIRCUIT DIAGRAM

ELEC

EF1000iS WIRING DIAGRAM

1

2

3

4

5

6

7

GENERAL SPECIFICATIONS SPEC Yamaha Generator Theory & Diagnostics Guide

SPECIFICATIONS

GENERAL SPECIFICATIONS Unit

EF1000iS

Model code number Dimensions: Overall length Overall width Overall height Dry weight

7VV2 mm (in) mm (in) mm (in) kg (lb)

450 (17.7) 240 (9.5) 380 (15.0) 12.7 (27.9)

Engine: Engine type Cylinder arrangement Displacement L (cm3) Bore × Stroke mm (in) Compression ratio Rated output 60 Hz · kW (PS) / 5,000 r / min Rated engine speed r / min Operating hours 60 Hz · Hrs W / no load W / rated load Fuel Fuel tank capacity L (lmp gal, US gal) Engine oil capacity L (lmp qt, US qt) Engine recomended oil

Electrical: Ignition system Ignition timing Spark plug type Spark plug gap Generator: Type Initial excitation Driving method Rated power factor

mm (in)

4-stroke OHV forced air cooled 1 0.050 (50) 41.0 × 38.0 (1.61 × 1.50) 8.2 : 1 1.21 (1.65) 5,000 12.0 4.3 Unleaded regular gasoline 2.5 (0.55, 0.66) 0.32 (0.28, 0.34) 4-stroke engine oil API service classification SE or SF, if not available, SD

TCI BTDC 33° CR6HSA (NGK) 0.7 ∼ 0.8 (0.028 ∼ 0.031) Multi pole rotating field magnet Permanent magnet Direct connection 1

7-1 3-4

Current Model Specifications and Wiring Diagram – EF1000iS

GENERAL SPECIFICATIONS Unit Frequency variation

EF1000iS

Instantaneous Settling Settling time Voltage fluctuation

Less than 1 % Less than 0.1 % Less than 7 sec

Instantaneous Settling Settling time AC output Rated voltage Frequency Rated output Rated current Safety device type

Less than 20 % Less than 3 % Less than 5 sec

Rated engine speed Voltage regulation Voltage stability Frequency stability Rotating speed control Wave distortion ratio Number of phase Insulation resistance Insulation type Receptacle

SPEC

V Hz kVA A AC DC r / min

Hz

MΩ AC DC

120 60 0.9 7.5 Electronic no fuse breaker Circuit breaker (No fuse breaker) 5,000 Voltage feed back system Within ± 4 % Within ± 1 Throttle motor control type Less than 2.5 % Triple phase Over 10 B type 15 A (Duples) × 2 8A×1

1 2 3 4 5 6 7

3-5

7-2

Yamaha Generator Theory & Diagnostics Guide MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Unit Piston: Piston clearance Piston skirt “ D ” Measuring point “ H ” Piston pin hole inside diameter Piston pin: Piston pin diameter Piston ring: Top ring Type Dimensions “ B × T ” End gap Side clearance 2nd ring Type Dimensions “ B × T ” End gap Side clearance OIl ring Type Dimensions “ B × T ” End gap Cylinder: Inside diameter “ D ” Taper limit Warpage limit Crankshaft: Big end side clearance “ A ” Runout “ B ” Crank pin diameter “ C ”

Connecting rod: Small end diameter “ A ” Oil clearance Small end diameter “ B ” Oil clearance

Standard

Limit

mm (in) 0.01 ~ 0.04 (0.0004 ∼ 0.0016) 40.95 ∼ 40.97 (1.612 ∼ 1.613) 10 mm (0.4) 10.000 ∼ 10.020 (0.3937 ∼ 0.3945)

0.1 (0.004) 40.94 (1.6118) ••• 10.050 (0.3956)

9.99 ∼ 10.00 (0.3933 ∼ 0.3937)

9.95 (0.3917)

Barrel face 0.8 × 1.6 (0.03 ∼ 0.06) 0.1 ~ 0.3 (0.0039 ∼ 0.0118) 0.06 ~ 0.11 (0.002 ~ 0.004)

••• ••• 0.6 (0.0236) 0.15 (0.006)

Taper 0.8 × 1.7 (0.03 ∼ 0.07) 0.10 ~ 0.3 (0.0039 ∼ 0.0118) 0.06 ~ 0.11 (0.002 ~ 0.004)

••• ••• 0.6 (0.0236) 0.15 (0.006)

Solid 1.5 × 1.9 (0.059 ∼ 0.075) 0.2 ~ 0.7 (0.0078 ∼ 0.0275)

••• ••• 0.9 (0.0354)

41.000 ∼ 41.010 (16.14 ∼ 16.15) ••• •••

41.10 (16.18) 0.05 (0.002) 0.05 (0.002)

0.2 ~ 0.65 (0.008 ~ 0.026) 15.970 ∼ 15.985 (0.629 ∼ 0.630)

0.7 (0.028) 0.03 (0.001) 15.940 (0.627)

10.006 ∼ 10.020 (0.3944 ∼ 0.3945) 0.015 ∼ 0.050 (0.0006 ∼ 0.0020) 16.000 ∼ 16.015 (0.6299 ∼ 0.6305) 0.015 ∼ 0.050 (0.0006 ∼ 0.0020)

10.050 (0.396) ••• 16.050 (0.632) •••

mm (in) mm (in)

B T

mm (in)

mm (in)

mm (in)

3-6

7-3

Current Model Specifications and WiringSPEC Diagram – EF1000iS MAINTENANCE SPECIFICATIONS

Unit

Standard

Camshaft: Camshaft outside diameter Cam dimension “A”

mm (in) IN 32.65 (1.29) 28.85 (1.14)

“B” Valve: Valve Stem diameter “ B ” Valve face contact width “ D ” Valve stem runout limit “θ” Valve guide Guide inside diameter Valve clearance (cold) Push rod: Runout limit Valve spring: Free length Set length Tilt limit

Limit

EX 32.65 (1.29) 28.85 (1.14)

mm (in) IN EX

3.96 ~ 3.98 (0.156 ~ 0.157) 3.94 ~ 3.96 (0.155 ~ 0.156)

3.92 (0.154) 3.90 (0.153)

IN EX

0.8 (0.03) 0.8 (0.03)

1.8 (0.07) 1.8 (0.07) 0.01 (0.0004) 90°

••• IN EX IN EX

4.0 4.0 0.1 0.1

(0.157) (0.157) (0.004) (0.004)

••• ••• ••• •••

mm (in) 0.5 (0.02)

•••

25.0 25.0 15.1 15.1 •••

24.0 (0.945) 24.0 (0.945) ••• ••• 2.0 (0.079)

mm (in) IN EX IN EX

3-7 7-4

(0.984) (0.984) (0.594) (0.594)

Yamaha GeneratorMAINTENANCE Theory & Diagnostics Guide SPECIFICATIONS SPEC Unit Carburetor: Type / manufacture I.D.mark Bore size Main jet Main air jet Pilot air jet Pilot outlet Valve seat size Main nozzle Pilot jet Throttle valve Float height “ H ”

Standard

Limit

mm (in) BV15-11 / MIKUNI 7VV 00 Ø 11 (0.433) #62.5 Ø 1.3 (0.051) Ø 0.9 (0.004) Ø 0.8 (0.031) Ø 1.5 (0.059) 2H #40 #110 1.5 (0.06)

3-8 7-5

••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• •••

Current ModelSPECIFICATIONS Specifications and Wiring SPEC Diagram – EF1000iS MAINTENANCE

GENERATOR AND ELECTRICAL Unit

Standard

Generator: AC coil 1 AC voltage (3 phase) (V/r/min) [Br - G (R - S), G - Br (S - T), Br - Br (R - T) With coupler disconnected] AC coil 2 AC voltage (3 phase) (V/r/min) [W - Or (R - S), Or - W (S - T), W - W (R - T) With coupler disconnected] DC coil DC voltage (V/r/min) Coil resistance AC coil 1 (Ω ± 20 %) [Br - G (R - S), G - Br (S - T), Br - Br (R - T) With coupler disconnected] AC coil 2 (Ω ± 20 %) [W - Or (R - S), Or - W (S - T), W - W (R - T) With coupler disconnected] DC coil (Ω ± 20 %) Electrical: Ignition system Ignition timing Ignition coil Primary coil resistance (Ω ± 20 %) Secondary coil resistance (kΩ ± 20 %) Spark plug cap resistance (kΩ) Spark plug minimum spark gap mm(in)

Limit

130 ~ 260 / 5,000

•••

13.5 ~ 23.0 / 5,000

•••

13.5 ~ 23.0 / 5,000

•••

0.47

•••

0.17

•••

0.07 (Blue-Blue)

•••

TCI BTDC 33°

••• •••

0.5 11.5 3.8 ~ 6.3 6 (0.24)

••• ••• ••• •••

7-6 3-9

Yamaha Generator Theory & Diagnostics Guide ELECTRICAL COMPONENTS ELEC INVERTER GENERATOR EF2400iS ELECTRICAL ELECTRICAL COMPONENTS 2

1

1 2 3 4 5 6 7 8 9 0 q w e r t y u

3 4 5

6 7 u 8

Engine switch Speed limiter Oil warning light (Red) Pilot light (Green) Overload warning light (Red) AC receptacle (20 A × 2) DC circuit breaker DC receptacle (12 V-8 A) Ground terminal TCI unit Control unit assembly Rectifier Generator assembly Oil level switch Spark plug Throttle control motor Twin tech (parallel running terminal)

9

0

e

r

t y

q

w

3-10 5-1

3-115-2

p

s

o

Or

B/W

L

G G Y Y R R L L Or Or

W W Or L W W Or L

L

W W W

4

i

B/W B/W Or Or

Or Or L B

Y Y Y

L

BW

L

G

Y

Or

R

Or Or

Y Y Y

u

6

Or

B/W

B

B/W

Y

0

R Br

L B/W Or Y G/Y

R

Br

W

Y

B/W

R

Br

Y

L

Or Or G/Y G/Y

r

R

Br

B

Y

B/W

t

7

Y

B/W

y

R

Br

e

w

8

G/Y

9

R

Br

G/Y

G/Y

G/Y

q

AC coil DC charge coil Sub coil Rectifier Generator assembly Control unit assembly Pilot light (Green) Twin tech(parallel running terminal) AC receptacle (20A × 2) Control box Ground terminal Overload warning light (Red) DC receptacle (12V-8A) DC circuit breaker Engine switch Oil warning light (Red) Speed limiter Oil level switch Magneto rotor TCI unit Spark plug Throttle control motor Engine assembly

COLOR CODE B ........Black Br .......Brown G........Green L.........Blue Or.......Orange R ........Red W .......White Y ........Yellow B/W....Black/White G/Y ....Green/Yellow

9 0 q w e r t y u i o p a s d

1 2 3 4 5 6 7 8

EF2400iS WIRING DIAGRAM

d

a

5

2 3

1

CIRCUIT DIAGRAM

Current Model Specifications and Wiring Diagrams – EF2400iS

CIRCUIT DIAGRAM

ELEC

1

2

3

4

5

6

7

Yamaha Generator Theory & Diagnostics Guide GENERAL SPECIFICATIONS SPEC SPECIFICATIONS

GENERAL SPECIFICATIONS Unit

EF2400iS

Model code number

1 2 3 4 5

Dimensions: Overall length Overall width Overall height Dry weight

7CF2 mm (in) mm (in) mm (in) kg (lb)

Engine: Engine type Cylinder arrangement Displacement L (cm3) Bore × Stroke mm (in) Compression ratio Rated output 60 Hz · kW (PS) / 5,000 r / min Rated engine speed r / min Operating hours 60 Hz · Hrs 1/4 rated load W / rated load Fuel Fuel tank capacity L (lmp gal, US gal) Engine oil capacity L (lmp qt, US qt) Engine recommended oil

6

1

527 (20.7) 419 (16.5) 461 (18.1) 32 (70.5) 4-stroke OHV forced air cooled 1 0.171 (171) 66.0 × 50.0 (2.60 × 1.97) 8.5 : 1 2.5 (3.4) 3,200 8.6 5.0 Unleaded regular gasoline 6.0 (1.32, 1.59) 0.6 (0.53, 0.63) 4-stroke engine oil API service classification SE or SF, if not available, SD

2 3 4 5 6

(5W-30)

7

7 Electrical: Ignition system Ignition timing Spark plug type Spark plug gap Generator: Type Initial excitation Driving method Rated power factor

mm (in)

TCI BTDC 23°±3° BPR4ES (NGK) 0.7 ∼ 0.8 (0.028 ∼ 0.031) Multi pole rotating field magnet Permanent magnet Direct connection 1

3-12 7-1

Current Model Specifications and Wiring Diagrams – EF2400iS

GENERAL SPECIFICATIONS Unit Frequency variation

EF2400iS

Instantaneous Settling Settling time Voltage fluctuation

Less than 1 % Less than 0.1 % Less than 1 sec

Instantaneous Settling Settling time AC output Rated voltage Frequency Rated output Rated current Safety device type

Less than 20 % Less than 3 % Less than 3 sec

Rated engine speed Voltage regulation Voltage stability Frequency stability Rotating speed control Wave distortion ratio Number of phase Insulation resistance Insulation type Receptacle

SPEC

V Hz kVA A AC DC r / min

Hz

MΩ AC DC

120 60 2.0 16.7 Electronic no fuse breaker Circuit breaker (No fuse breaker) 3,200 Voltage feed back system Within ± 1 % Within ± 0.1 Throttle motor control type Less than 2.5 % Single phase Over 10 B type 20 A (Duples) × 2 8A×1

1 2 3 4 5 6 7

3-13

7-2

Yamaha GeneratorMAINTENANCE Theory & Diagnostics Guide SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Unit Piston: Piston clearance Piston skirt “ D ” Measuring point “ H ” Piston pin hole inside diameter Piston pin: Piston pin diameter Piston ring: Top ring Type Dimensions “ B × T ” End gap Side clearance 2nd ring Type Dimensions “ B × T ” End gap Side clearance OIl ring Type Dimensions “ B × T ” End gap Cylinder: Inside diameter “ D ” Taper limit Warpage limit Crankshaft: Big end side clearance “ A ” Runout “ B ” Crank pin diameter “ C ”

Connecting rod: Small end diameter “ A ” Oil clearance Small end diameter “ B ” Oil clearance

Standard

Limit

mm (in) 0.015 ~ 0.040 (0.0006 ∼ 0.0016) 66.0 (2.598) 10 mm (0.4) 16.002 ∼ 16.013 (0.6300 ∼ 0.6304)

0.1 (0.004) 65.9 (2.594) ••• 16.020 (0.6307)

mm (in) 15.995 ∼ 16.000 (0.0.6297 ∼ 0.6299) 15.950 (0.6280) mm (in)

B T

Barrel face 1.5 × 2.7 (0.059 ∼ 0.106) 0.2 ~ 0.4 (0.008 ∼ 0.016) 0.04 ~ 0.08 (0.0016 ~ 0.0031)

••• ••• 0.9 (0.0354) 0.1 (0.0039)

Taper 1.5 × 2.7 (0.059 ∼ 0.106) 0.2 ~ 0.4 (0.008 ∼ 0.016) 0.02 ~ 0.06 (0.0008 ~ 0.0024)

••• ••• 0.9 (0.0354) 0.1 (0.0039)

Solid 2.5 × 2.7 (0.098 ∼ 0.106) 0.2 ~ 0.4 (0.008 ∼ 0.016)

••• ••• 0.9 (0.0354)

66.00 ∼ 66.02 (2.5984 ∼ 2.5990) ••• •••

66.020 (2.5990) 0.05 (0.002) 0.05 (0.002)

0.2 ~ 0.60 (0.008 ~ 0.024) ••• 28.0 (1.102)

0.75 (0.029) 0.04 (0.0016) 27.9 (1.098)

16.006 ∼ 16.020 (0.6301 ∼ 0.6307) 0.006 ∼ 0.025 (0.0002 ∼ 0.0010) 28.000 ∼ 28.015 (1.1023 ∼ 1.1029) 0.015 ∼ 0.040 (0.0006 ∼ 0.0016)

••• ••• ••• 0.1 (0.004)

mm (in)

mm (in)

mm (in)

3-14 7-3

Current Model Specifications and Wiring Diagrams – EF2400iS MAINTENANCE SPECIFICATIONS SPEC

Unit

Standard

Camshaft: Camshaft outside diameter Cam dimension “A”

mm (in) IN 26.9 ±0.05 (1.06 ±0.002) 22.0 ±0.05 (0.87 ±0.002) 14.965 ~ 14.990 (0.5892 ~ 0.5902)

“B” Camshaft diameter Valve: Valve Face diameter “ A ” Stem diameter “ B ” Stem length

“C”

Valve face contact width “ D ”

Limit

EX 26.68 ±0.05 (1.05 ±0.002) 22.03 ±0.05 (0.87 ±0.002) 14.950 (0.59)

mm (in) IN EX IN EX IN EX

24.0 (0.94) 22.0 (0.87) 5.5 (0.22) 5.5 (0.22) 65.9 (2.59) 66.2 (2.61)

••• ••• ••• ••• ••• •••

IN EX

0.7 (0.03) 0.7 (0.03) ••• •••

1.7 (0.067) 1.7 (0.067) 0.01 (0.0004) 90°

5.5 (0.22) 5.5 (0.22) 0.04 ~ 0.06 (0.0016 ∼ 0.0020) 0.06 ~ 0.08 (0.002 ∼ 0.003) 0.1 (0.004) 0.1 (0.004)

5.4 (0.21) 5.4 (0.21) ••• ••• ••• •••

0.5 (0.02)

•••

26.5 (1.04) 26.5 (1.04) 21.6 (0.85) 21.6 (0.85) 4.5 kg (9.9 lb) 4.5 kg (9.9 lb) •••

25.0 (0.98) 25.0 (0.98) ••• ••• ••• ••• 1.6 (0.06)

Valve stem runout limit “θ” Valve guide Guide inside diameter

IN EX Stem to guide clearance IN EX Valve clearance (cold) IN EX Push rod: Runout limit Valve spring: Free length IN EX Set length IN EX Set force IN EX Tilt limit

mm (in) mm (in)

3-15

7-4

Yamaha GeneratorMAINTENANCE Theory & Diagnostics Guide SPECIFICATIONS SPEC Unit Carburetor: Type / manufacture I.D.mark Bore size Main jet Main air jet Pilot air jet Pilot outlet Valve seat size Main nozzle Pilot jet Throttle valve Float height “ H ”

Standard

Limit

mm (in) BV20-15 / MIKUNI 7CF 10 Ø 15 (0.5906) #86.3 Ø 1.8 (0.0709) Ø 1.1 (0.0433) Ø 0.9 (0.0354) Ø 1.8 (0.0709) 31B #35 #150 16.0 (0.63)

3-16 7-5

••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• •••

SPEC – EF2400iS MAINTENANCE Current Model SPECIFICATIONS Specifications and Wiring Diagrams GENERATOR AND ELECTRICAL Unit

Standard

Generator: Main coil AC voltage (3 phase) (V/r/min) (With the throttle control motor coupler disconnected) Sub coil AC voltage (single phase) (V/r/min) (With the throttle control motor coupler disconnected) DC coil DC voltage (V/r/min) Coil resistance Main coil (Ω ± 20 %) [Br - G (R - S), G - Br (S - T), Br - Br (R - T) With coupler disconnected] Sub coil (Ω ± 20 %) [W - Or (R - S), Or - W (S - T), W - W (R - T) With coupler disconnected] DC coil (W ± 20 %) [W - W (L-L) With 4P coupler disconnected] Electrical: Ignition system Ignition timing Ignition coil Primary coil resistance Secondary coil resistance Spark plug cap resistance Spark plug minimum spark gap

(Ω ± 20 %) (kΩ ± 20 %) (kΩ) mm(in)

Limit

175 ~ 225 / 2,600

•••

13.0 ~ 18.0 / 2,600

•••

17.0 ~ 23.0 / 2,600

•••

1.22

•••

0.19

•••

0.12

•••

TCI BTDC 23°±3°

••• •••

1.35 6.8 4.0 ~ 6.0 6 (0.24)

••• ••• ••• •••

7-6

3-17

Yamaha Generator Theory & Diagnostics Guide ELECTRICAL COMPONENTS ELEC CONVENTIONAL GENERATOR EF2600 ELECTRICAL

ELECTRICAL COMPONENTS

1 2 3 4 5 6 7 8 9 0 q w e

3

2

4

1

w 5 q

0 6 9 8 e

7

3-18 6

Oil warning unit TCI unit Spark plug Condenser Stator assembly Rotor assembly Oil level switch G.F.C.I. receptacle AC switch (NFB) Voltmeter Engine switch Oil warning light AC receptacle

7

3-19

e

B

B

1

CIRCUIT DIAGRAM

w

q B/W

G G

2 R

B

G G

B/W

Br

G G

G G

B/W

L

G/Y

R

Br

B/W

Y

r

G G

R

Br V

0

L Y B/W B

3

4

8 B/W B

9

R

Br

R

Br

5

B

G/Y G/Y

G/Y

Br

7

R

770-053a

6

G/Y

Rotor assembly Stator assembly Voltmeter AC switch (NFB) G.F.C.I. receptacle AC receptacle Ground (earth) terminal Engine switch Condenser Oil warning unit T.C.I unit Spark plug Oil level switch Oil warning light

COLOR CODE B ........Black Br .......brown G........Green L.........Blue R ........Red Y ........Yellow B/W....Black/White G/Y ....Green/Yellow

1 2 3 4 5 6 7 8 9 0 q w e r

Current Model Specifications and Wiring Diagrams – EF2600

CIRCUIT DIAGRAM

ELEC

EF2600 WIRING DIAGRAM

GENERAL SPECIFICATIONS SPEC Yamaha Generator Theory & Diagnostics Guide

SPECIFICATIONS

GENERAL SPECIFICATIONS Unit

EF2600 7CA2

Model code number Dimensions: Overall length Overall width Overall height Dry weight

mm (in) mm (in) mm (in) kg (lb)

510 (20.1) 415 (16.3) 425 (16.7) 41 (90.4)

Engine: Engine type Cylinder arrangement Displacement L (cm3) Bore × Stroke mm (in) Compression ratio Rated output kW (PS) / 3600 r / min Rated engine speed r / min Operating hours Hrs Fuel Fuel tank capacityL (lmp gal, US gal) Engine oil capacityL (lmp qt, US qt) Engine recommended oil

4-stroke OHV forced air cooled 1 0.171 (171) 66.0 × 50.0 (2.60 × 1.97) 8.5 : 1 3.3 (4.4) 3600 9.0 Unleaded regular gasoline 12.0 (2.64, 3.17) 0.6 (0.53, 0.63) 4-stroke engine oil API service classification SE or SF, if not available, SD (5W-30)

Engine speed with no load

3,700 ∼ 3,850 r/min

Electrical: Ignition system Ignition timing Spark plug type Spark plug gap

TCI BTDC 23° ± 3° / 3600 r / min BPR4ES (NGK) 0.7 ∼ 0.8 (0.028 ∼ 0.031)

mm (in)

8 3-20

Current Model Specifications and Wiring Diagrams – EF2600 GENERAL SPECIFICATIONS SPEC

Unit

EF2600

Generator: Type AC output Rated voltage Frequency Rated output Rated current Safety device system Excitation Initial excitation AC voltage fluctuation AC frequency variation Wave distortion ratio Rated power factor Number of phase Number of poles Driving method Receptacle

Brush-less, self-exiting, single phase synchronous generator V Hz kVA A

AC

120 60 2.3 19.2 NFB/G.F.C.I. Self magnetization Residual magnetization Less than 10 % Less than 5 % Less than 25 % 1.0 Single phase 2 Direct connection 20A,125V × 2 (G.F.C.I.) and 20A,125V × 1

3-21 9

Yamaha GeneratorMAINTENANCE Theory & Diagnostics Guide SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Unit Camshaft: Camshaft outside diameter

Standard mm (in) 14.973 ~ 14.989 (0.5895 ~ 0.5901) •••

Camshaft runout limit Cam dimension “A”

14.95 (0.589) 0.1 (0.0004)

26.9 (1.059) ± 0.05 (0.002)

26.8 (1.055)

± 0.05 (0.002)

22.025 (0.867) ± 0.05 (0.002) 21.925 (0.863) ± 0.05 (0.002)

“B” Carburetor: Type / Quantity I.D.mark Bore size Main jet Main air jet Pilot air jet Pilot outlet Valve seat size Main nozzle Pilot jet Throttle valve Float height “ H ” Governor arm Tension spring attach hole

Limit

mm (in) BV20 / 1 7NJ-10 Ø 15 (0.590) #91.3 Ø 1.8 (0.071) Ø 1.1 (0.043) Ø 0.9 (0.035) Ø 1.8 (0.070) 31A #41.3 #150 16 (0.630) 4

3-22 10

••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• ••• 1 2

3 4

5

•••

MAINTENANCE SPECIFICATIONS SPEC Current Model Specifications and Wiring Diagrams – EF2600 GENERATOR AND ELECTRICAL Unit Generator: Coil resistance Main coil Sub coil Rotor coil Electrical: Ignition system Ignition timing TCI Primary coil resistance Secondary coil resistance Air gap

Standard

Limit

(Ω ± 20 %) 0.84 (Red-Brown) 1.6 (Green-Green) 1.8

••• ••• •••

TCI ••• BTDC 23° ± 3° / 3600 r / min ••• (Ω ± 20 %) 1.2 (kΩ ± 20 %) 11.7 mm (in) 0.4 ~ 0.6 (0.016 ~ 0.023)

11

3-23

••• ••• •••

Yamaha Generator Theory & Diagnostics Guide SPEC WIRE ROUTING DIAGRAM

WIRE ROUTING DIAGRAM CONTROL BOX PANEL AND BEHIND CONTROL BOX 1 2 3 4 5 6 7 8

Engine switch Oil warning light Voltmeter AC switch (NFB) G.F.C.I. receptacle AC receptacle Condenser Oil warning unit

COLOR CODE B ........Black Br .......brown G........Green R ........Red Y ........Yellow B/W....Black/White G/Y ....Green/Yellow

å Control box panel ∫ Behind the control box panel ç Behind the control box

23 4

1

6

5

å

8 G G/Y

G

7 ∫

Br

G/Y

R Br

B/W

R

Br

R R

B Y B/W

Br Br

Br

ç

3-24

12

G/Y

Current Model Specifications and Wiring Diagrams – EF2800i

INVERTER GENERATOR EF2800i

3-25

Yamaha Generator Theory & Diagnostics Guide EF2800i WIRING DIAGRAM

3-26

Current Model Specifications and Wiring Diagrams – EF2800i

(5W-30)

3-27

Yamaha Generator Theory & Diagnostics Guide

3-28

Current Model Specifications and Wiring Diagrams – EF2800i

3-29

Yamaha Generator Theory & Diagnostics Guide

3-30

Current Model Specifications and Wiring Diagrams – EF2800i

3-31

Yamaha Generator Theory & Diagnostics Guide

3-32

– + /B Current Model Specifications and Wiring Diagrams – EF3000iSE ELECTRICAL COMPONENTS INVERTER GENERATOR EF3000iSE / B

ELEC

ELECTRICAL ELECTRICAL COMPONENTS 1 Generator assembly 2 Oil level switch 3 Starter motor 4 Control unit 5 Charging coil 6 Starter relay 7 Rectifier 8 Battery 9 Flywheel 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 receptacle (20 A) J AC receptacle (30 A) K Ground terminal L Overload warning light (Red) M Pilot light (Green) N DC circuit breaker O Oil level warning light (Red)

1 3

2

SWL4010

D C B A 0 9 8

4 5 6 7

E

F

G

SWL4020

I

H

J

SWL4030

O

N

M

3-33 4-1

L

K

4

GENERAL SPECIFICATIONS SPEC Yamaha Generator Theory & Diagnostics Guide

SPECIFICATIONS GENERAL SPECIFICATIONS Unit Model code number Dimensions: Overall length Overall width Overall height Dry weight

EF3000iSE/EF3000iSEB 7WL2 mm (in) mm (in) mm (in) kg (lb)

Engine: Engine type Cylinder arrangement Displacement L (cm3) Bore × Stroke mm (in) Compression ratio Standard compression pressure kPa (kg/cm2, psi) Rated output 60 Hz · kW (PS)/3,800 r/min Operating hours 60 Hz · Hrs 1/4 load (economy switch is on) Rated load (economy switch is on) Fuel Fuel tank capacity L (Imp gal, US gal) Engine oil quantity L (Imp qt, US qt) Engine oil grade

680 (26.8) 445 (17.5) 555 (21.9) 67 (147.7) (EF3000iSE) 69 (152.1) (EF3000iSEB) 4-stroke, OHV, forced air cooled 1 0.171 (171) 66.0 × 50.0 (2.60 × 1.97) 8.5:1 400 ~ 600 (4 ~ 6, 57 ~ 85) 3.5 (4.7) 20.5 8.0 Unleaded regular gasoline 13.0 (2.86, 3.43) 0.6 (0.53, 0.63) 4-stroke engine oil API service classification SE or SF, if not available, SD

(5W-30)

Electrical: Ignition system Spark plug type Gap

mm (in)

TCI BPR4ES (NGK) 0.7 ~ 0.8 (0.028 ~ 0.031)

5-1 3-34

SPEC

Current Model Specifications and Wiring Diagrams – EF3000iSE / B

GENERAL SPECIFICATIONS

Unit Generator: Type Initial excitation Driving method Rated power factor Frequency variation Instantaneous Settling Settling time Voltage fluctuation Instantaneous Settling Settling time AC output Rated voltage Frequency Rated output Rated current DC output Rated voltage Rated current Safety device type Engine speed (no load) Rated engine speed Economy engine speed (no load) Voltage regulation Voltage stability Frequency stability Rotating speed control Wave distortion ratio Number of phase AC output (main coil) DC output (subcoil) Insulation resistance Insulation type Receptacle

EF3000iSE/EF3000iSEB Multi pole rotating field magnet Permanent magnet Direct connection 1.0 Less than 1% Less than 0.1% Less than 1 sec Less than 20% Less than 3% Less than 2 sec V Hz kVA A V A AC DC r/min r/min r/min

Hz

MΩ AC DC

120 60 2.8 23.3 12 12 Electronic no fuse breaker Circuit breaker (No fuse breaker) 3,800 3,800 2,800 ± 50 Voltage feed back system Within ± 4% Within ± 1.0 Throttle motor control type Less than 2.5% Three phase Single phase Over 10 B type 20 A (Duples) × 1, 30 A × 1 12 A × 1

3-35 5-2

5

Yamaha Generator Theory & Diagnostics Guide SPEC MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS ENGINE Unit

EF3000iSE/EF3000iSEB

Piston: mm (in) Piston clearance <Limit> Piston skirt “D” <Limit> Measuring point “H” Oversize 1st 2nd Piston pin hole inside diameter <Limit> Piston pin: mm (in) Piston pin diameter <Limit> Piston ring: mm (in) Top ring B Type T Dimensions “B × T” End gap <Limit> Side clearance <Limit> 2nd ring B Type T Dimensions “B × T” End gap <Limit> Side clearance <Limit> Oil ring B Type T Dimensions “B × T” End gap <Limit> Cylinder head: mm (in) Warpage limit Cylinder: mm (in) Inside diameter “D” <Limit> Taper limit

0.015 ~ 0.040 (0.00059 ~ 0.00157) 0.15 (0.00591) 65.975 ~ 65.990 (2.5974 ~ 2.5980) 65.9 (2.5945) 10.0 (0.4) 66.225 ~ 66.240 (2.6072 ~ 2.6079) 66.475 ~ 66.490 (2.6171 ~ 2.6177) 16.002 ~ 16.013 (0.6300 ~ 0.6304) 16.043 (0.6316) 15.995 ~ 16.000 (0.6297 ~ 0.6299) 16.043 (0.6316)

Barrel face 1.5 × 2.7 (0.0591 × 0.1063) 0.20 ~ 0.40 (0.0079 ~ 0.0157) 0.65 (0.0256) 0.04 ~ 0.08 (0.0016 ~ 0.0031) 0.13 (0.0051) Taper 1.5 × 2.7 (0.0591 × 0.1063) 0.20 ~ 0.40 (0.0079 ~ 0.0157) 0.75 (0.0295) 0.02 ~ 0.06 (0.0008 ~ 0.0024) 0.12 (0.0047) Solid 2.5 × 2.8 (0.0984 × 0.1102) 0.20 ~ 0.70 (0.0079 ~ 0.0276) 0.9 (0.0354) 0.05 (0.0020) 66.005 ~ 66.015 (2.5986 ~ 2.5990) 66.020 (2.5992) 0.05 (0.0020)

3-36 5-3

Current Model Specifications and Wiring Diagrams – EF3000iSE / B

MAINTENANCE SPECIFICATIONS Unit

EF3000iSE/EF3000iSEB

Crankshaft: Big end side clearance “A” <Limit> Runout “B” <Limit> Crankshaft pin diameter “C” <Limit> Connecting rod: Small end diameter “A” Oil clearance Big end diameter “B” Oil clearance <Limit> Camshaft: Camshaft outside diameter Cam dimension “A”

mm (in) 0.2 ~ 0.6 (0.0079 ~ 0.0236) 0.8 (0.0315) 0.02 (0.0008) 27.969 ~ 27.984 (1.1011 ~ 1.1017) 27.9 (1.0984) mm (in) 16.006 ~ 16.020 (0.6302 ~ 0.6307) 0.007 ~ 0.018 (0.0003 ~ 0.0007) 28.000 ~ 28.015 (1.1024 ~ 1.1030) 0.015 ~ 0.040 (0.0006 ~ 0.0016) 0.1 (0.0039) mm (in) IN 26.9 ± 0.05 (1.059 ± 0.002) 22.0 ±0.05 (0.866 ± 0.002)

“B”

Camshaft journal <Limit> Valve: Valve Face diameter “A” Stem diameter “B” <Limit> Stem length “C” Valve face contact width “D” <Limit> Valve stem runout limit “θ”

SPEC

EX 26.68 ± 0.05 (1.050 ± 0.002) 22.025 ± 0.05 (0.867 ± 0.002)

14.965 ~ 14.990 (0.5892 ~ 0.5902) 14.950 (0.5886) mm (in) IN EX IN EX IN EX IN EX

23.9 ~ 24.1 (0.9409 ~ 0.9488) 21.9 ~ 22.1 (0.8622 ~ 0.8701) 5.448 ~ 5.463 (0.2145 ~ 0.2151) 5.440 ~ 5.445 (0.2142 ~ 0.2144) 5.418 (0.2133) 5.410 (0.2130) 65.9 (2.59) 66.2 (2.61)

IN EX

0.9 ~ 1.1 (0.0354 ~ 0.0433) 0.9 ~ 1.1 (0.0354 ~ 0.0433) 1.6 (0.0630) 0.01 (0.0004) 90°

3-37 5-4

Yamaha Generator Theory & Diagnostics Guide MAINTENANCE SPECIFICATIONS

Unit Valve guide Guide inside diameter

IN EX <Limit> IN EX Stem to guide clearance IN EX Valve clearance (cold) IN EX Push rod: mm (in) Runout limit Valve spring: mm (in) Free length IN EX <Limit> IN EX Set length IN EX Set force IN N (kg, lb) EX N (kg, lb) Tilt limit Degree/mm (in) Carburetor: mm (in) Type/manufacturer I.D. mark Bore size Main jet Min air jet Pilot air jet Pilot outlet Valve seat size Main nozzle Pilot jet Throttle valve Float height “H” Ω ± 7% Throttle control motor resistance

SPEC

EF3000iSE/EF3000iSEB 5.5 (0.22) 5.5 (0.22) 5.4 (0.21) 5.4 (0.21) 0.04 ~ 0.06 (0.0016 ~ 0.0024) 0.06 ~ 0.08 (0.0024 ~ 0.0031) 0.18 ~ 0.22 (0.007 ~ 0.009) 0.18 ~ 0.22 (0.007 ~ 0.009) 0.5 (0.02) 26.5 (1.04) 26.5 (1.04) 25.2 (0.99) 25.2 (0.99) 21.6 (0.85) 21.6 (0.85) 41.9 ~ 46.3 (4.2 ~ 4.6, 92.4 ~ 102.1) 41.9 ~ 46.3 (4.2 ~ 4.6, 92.4 ~ 102.1) 2.5/1.6 (0.06) BV20-15/MIKUNI 7WL 00 ø15 #101.3 ø1.8 ø1.1 ø0.9 ø1.8 31B #37.5 #150 16.0 (0.63) 250

3-38 5-5

Current Model Specifications and Wiring Diagrams – EF3000iSE / B

MAINTENANCE SPECIFICATIONS

SPEC

GENERATOR AND ELECTRICAL Unit Generator: Type/manufacturer Main coil AC voltage (3 phase) V Subcoil AC voltage (single phase) V Coil resistance Ω ± 10% Main coil Ω ± 10% Subcoil Ω ± 10% Subcoil Electrical: Ignition timing at 3,600 r/min TCI unit Ω ± 20% Primary coil resistance Ω ± 20% Secondary coil resistance Air gap between TCI unit and flywheel magneto mm (in) Ω ± 20% Charge coil resistance Spark plug cap resistance kΩ Minimum spark gap mm (in) Battery Type/manufacturer Charging amperage and charging time A × hr Charging voltage V Starter motor Brush length mm (in) <Limit> Brush spring force N (g, lb) Commutator diameter mm (in) <Limit> Mica undercut mm (in) Fuse Main A

EF3000iSE/EF3000iSEB GP9822/KOKUSAN DENKI 200 ~ 240 13.5 ~ 23.0 0.79 (Yellow-Yellow) 0.17 (Orange-Orange) 0.07 (Blue-Blue) BTDC 23 ± 3° 0.5 11.5 0.5 ± 0.1 (0.020 ± 0.004) 0.35 (white-ground) 3.8 ~ 6.3 7 (0.28) or more YTX12-BS/YUASA 1.2 × 5 ~ 10 12.8 or more 10 (0.39) 3.5 (0.14) 5.5 ~ 8.3 (550 ~ 830, 12.1 ~ 18.3) 22 (0.87) 21 (0.83) 1.5 (0.06) 10 × 1

3-39

5-6

Yamaha Generator Theory & Diagnostics Guide ELECTRICAL COMPONENTS ELEC

ñ

+

COMPONENT LOCATION DIAGRAM ELECTRICAL

ELECTRICAL COMPONENTS EF4000DE 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L

Main switch Economy switch Oil warning light Voltage meter AC switch (120 V, NFB) AC switch (240 V, NFB) AC receptacle (120 V-20 A) AC receptacle (120 V-30 A) AC receptacle (120/240 V-20 A) Stator assembly Rotor assembly Ground terminal Oil level switch Spark plug TCI unit Condenser Oil warning unit Fuse(10 A) Economy idle unit Rectifier Rectifier/regulator Solenoid valve

4 3 2 1

56

78 9 0A

B C SVW4010

E D

SVW4020

F

G

I J

H

L

K

G/Y

B

B/W R

Y Br

Br

Br Y

Y Y

B/W

R

R Br

Br

G/Y

R

R Br G/Y

Br G/Y

L L

L

SVW4030

3-40

4-1

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; YG4000DE

3-41

Yamaha Generator Theory & Diagnostics Guide INVERTER GENERATOR EF4000DE

3-42

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; YG4000DE

(5W-30)

3-43

Yamaha Generator Theory & Diagnostics Guide

3-44

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; YG4000DE

3-45

Yamaha Generator Theory & Diagnostics Guide

3-46

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; YG4000DE

3-47

Yamaha Generator Theory & Diagnostics Guide

3-48

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; YG4000DE

3-49

Yamaha Generator Theory & Diagnostics Guide INVERTER GENERATOR EF4500iSE

3-50

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF4500iSE EF4500iSE WIRING DIAGRAM

3-51

Yamaha Generator Theory & Diagnostics Guide

3-52

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF4500iSE

(5W-30)

3-53

Yamaha Generator Theory & Diagnostics Guide

3-54

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF4500iSE

3-55

Yamaha Generator Theory & Diagnostics Guide

3-56

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF4500iSE

3-57

Yamaha Generator Theory & Diagnostics Guide

3-58

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF4500iSE

3-59

Yamaha Generator Theory & Diagnostics Guide

3-60

Current Model Specifications and Wiring Diagrams – ñ + EF5200DE

ELEC

ELECTRICAL COMPONENTS CONVENTIONAL GENERATOR EF5200DE

ELECTRICAL

ELECTRICAL COMPONENTS EF5200DE 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O

Main switch Economy switch Oil warning light Voltage meter AC receptacle (125 V-20 A) AC receptacle (125 V-30 A) AC receptacle (125/250 V-20 A) AC switch (120 V, NFB) AC switch (240 V, NFB) Exciter field coil Stator assembly Rotor assembly Oil level switch Spark plug TCI unit Resistor Oil warning unit Rectifier AVR Condenser Economy idle unit Ground terminal Fuse (10 A) Rectifier/regulator Solenoid valve

PVX0030

PVX0040

G/Y

B

Y

G

PVX0050

2

3-61

B/W

G/Y

W

G/R

4

3-62 M

R/W

B W

Y G G

R

B W

B W

G/R

Br

Br

B W

R

R

Y G G

L

L

Y Y G G G G

B

1 2 3 4 5 6 7 8

COLOR CODE B ............ Black Br........... Brown G ........... Green

120V

240V Y

Br

Rotor assembly Stator assembly Main coil Sub coil Exciter field coil Voltage meter AC switch (NFB) AC receptacle (125 V-20 A)

L B/W R/W W G/R G/R B R

Y

Y

G

R Br

R

G Y L/W G Y L/W

B W W G B Y R G

B/W

B/W

V

Y

Y

B W W G B Y R G

Br

R

L

L Y B/W B

L G/B R/W

G/Y

G/R

R

W R G/R W

Br

G/Y R

R

B

Br

R

G/Y

F G H I J K L M N

B/W

Br R

B

B/W Br

B

G/R L/W B Y

R B/W R/W

R

B B/W Br R

R/W B B Br R B/W B/W R

STOP ON START

B G/R G/R B L/W Y Y L/W

R/B

R/W

B R/B R B/W R/W Br

G/Y

Rectifier/regulator Voltage adjuster AVR Condenser Economy idle unit Oil warning unit Oil warning light Solenoid valve Economy switch

B

L

B

G/R L/W B Y

R

B/W ........Black/White G/B.........Green/Black G/Y.........Green/Yellow G/R ........Green/Red

9 AC receptacle (125 V-30 A) 0 AC receptacle (125/250 V-20 A) A Ground terminal B Main switch C Remote control terminal D Rectifier E Fuse (10 A)

Br

R

L ............ Blue R ........... Red W........... White Y............ Yellow

O P Q R S T U V

Battery Carburetor heater Starter motor Starter relay Charging coil TCI unit Spark plug Oil level switch

L/W ........ Blue/White R/B ........ Red/Black R/W ....... Red/White

EF5200DE WIRING DIAGRAM

B

B

G

EF5200DE

CIRCUIT DIAGRAM

Yamaha Generator Theory & Diagnostics Guide CIRCUIT DIAGRAM

ELEC ñ

PVX0090

+

Current Model Specifications and Wiring Diagrams – EF5200DE

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS GENERAL SPECIFICATIONS Unit

EF5200DE

Model code number Dimensions: Overall length Overall width Overall height Dry weight Engine: Engine type

mm (in) mm (in) mm (in) kg (lb)

Cylinder arrangement Displacement Bore × Stroke

←

894 (35.2) 520 (20.5) 510 (20.1) 87 (191.4)

670 (26.4) 510 (20.1) 560 (22.0) 83 (182.6)

← 4-stroke OHV forced air cooled ← 1 ← 0.301 (301) ← 78.0 × 63.0 (3.07 × 2.48) ← 8.1 : 1 ← 5.8 (7.9) ← 7.6 Unleaded regular gas- ← oline ← 21.0 (4.62, 5.55) ← 1.1 (0.97, 1.16) 4-stroke engine oil API service classification SE or SF, if not available, SD

L (cm3) mm (in)

Compression ratio Rated output 60 Hz ∑kW (PS)/3,600 r/min Operating hours 60 Hz ∑Hrs Fuel Fuel tank capacity Engine oil capacity Engine oil grade

YG5200D

7VX2

L (Imp gal, US gal) L (Imp qt, US qt)

(5W-30)

Electrical: Ignition system Ignition timing at 3,600 r/min Spark plug type Gap

TCI BTDC 25 ± 3∞ BPR4ES (NGK) 0.7 ~ 0.8 (0.028 ~ 0.031)

mm (in)

6

3-63

← ← ← ←

Yamaha Generator Theory & Diagnostics Guide SPEC GENERAL SPECIFICATIONS

Unit

EF5200DE

Generator: Type

Number of phase Number of poles Excitation Initial excitation Driving method Rated power factor Frequency variation Voltage fluctuation AC output Rated voltage Frequency Rated output Rated current Safety device type Rated engine speed Economy idle engine speed Voltage regulation Insulation resistance Insulation class Stator Rotor Receptacle AC

V Hz kVA A r/min r/min MΩ

YG5200D

Brushless, self-exciting, single-phase, synchronous generator Single phase 2 Self magnetization Residual magnetization Direct connection 1.0 Less than 5% Less than 10%

←

120/240 60 4.5 37.5/18.8 NFB (No fuse breaker) 3,600 2,350 AVR 10

← ← ← ← ← ← ← ← ←

E class B class

← ←

20 A (125 V) × 2, 30 A (125 V) × 1, 20 A (250/125 V) × 1

←

7

3-64

← ← ← ← ← ← ← ←

Current Model Specifications and Wiring Diagrams – EF5200DE

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS ENGINE Unit Piston: Piston clearance

EF5200DE mm (in) 0.024 ~ 0.038 (0.00094 ~ 0.00150) 0.100 (0.0039) 77.960 ~ 77.980 (3.0693 ~ 3.0701) 77.900 (3.067) 10.0 (0.4) 78.25 (3.0807) 78.50 (3.0906) 20.000 (0.7874) 20.020 (0.7882)

<Limit> Piston skirt ìDî <Limit> Measuring point ìHî Oversize 1st 2nd Piston pin hole inside diameter <Limit> Piston pin: Piston pin diameter <Limit> Piston ring: Top ring Type Dimensions ìB × Tî

YG5200D ← ← ← ← ← ← ← ← ←

mm (in) 19.995 ~ 20.000 (0.7872 ~ 0.7874) 19.950 (0.7854)

← ←

mm (in) Barrel face 1.5 × 3.5 (0.059 × 0.138) 0.2 ~ 0.4 (0.008 ~ 0.016) 0.9 (0.0354) 0.04 ~ 0.08 (0.0016 ~ 0.0031) 0.1 (0.0039)

End gap <Limit> Side clearance <Limit> 2nd ring Type Dimensions ìB × Tî

Taper 1.5 × 3.5 (0.059 × 0.138) 0.2 ~ 0.4 (0.008 ~ 0.016) 0.9 (0.0354) 0.03 ~ 0.07 (0.0012 ~ 0.0028) 0.1 (0.0039)

End gap <Limit> Side clearance <Limit> Oil ring Type Dimensions ìB × Tî

3-piece type 2.5 × 2.8 (0.098 × 0.110) 0.2 ~ 0.7 (0.008 ~ 0.028) 0.9 (0.0354)

End gap <Limit> 8

3-65

← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

Yamaha Generator Theory & Diagnostics Guide MAINTENANCE SPECIFICATIONS

Unit Cylinder head: Warpage limit Cylinder: Inside diameter ìDî <Limit> Taper limit Warpage limit Crankshaft: Big end side clearance ìAî

EF5200DE

<Limit> Camshaft journal diameter <Limit>

78.000 ~ 78.020 (3.0709 ~ 3.0716) 78.020 (3.0716) 0.05 (0.002) 0.05 (0.002)

←

0.20 ~ 0.65 (0.008 ~ 0.026) 0.8 (0.032) 0.04 (0.0016) 35.969 ~ 35.984 (1.4161 ~ 1.4167) 35.9 (1.4134)

← ← ← ← ← ← ← ←

mm (in) 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)

Oil clearance

ìBî

←

mm (in)

Big end diameter ìBî

<Limit>

0.05 (0.002) mm (in)

Oil clearance

<Limit> Camshaft: Camshaft outside diameter Cam dimension ìAî

YG5200D

mm (in)

<Limit> Runout ìBî <Limit> Crank pin outside diameter ìCî <Limit> Connecting rod: Small end diameter ìAî

SPEC

← ← ← ← ←

mm (in) IN EX 32.55 ± 0.05 32.55 ± 0.05 (1.28 ± 0.002) (1.28 ± 0.002) 32.40 32.40 (1.276) (1.276) 26.08 ± 0.05 26.08 ± 0.05 (1.03 ± 0.002) (1.03 ± 0.002) 25.93 25.93 (1.021) (1.021) 15.965 ~ 15.990 (0.6285~ 0.6295) 15.950 (0.6280)

9

3-66

IN

EX

←

←

←

←

←

←

←

←

← ←

Current Model Specifications and Wiring Diagrams – EF5200DE

MAINTENANCE SPECIFICATIONS Unit Valve: Valve Face diameter ìAî Stem diameter ìBî

EF5200DE

EX <Limit> Stem length ìCî Valve face contact width ìDî

IN EX IN EX IN EX

<Limit> Valve stem runout limit ìθî Valve guide Guide inside diameter IN

Stem to guide clearance IN EX IN EX Push rod: Runout limit Valve spring: Free length <Limit> Set length Set force

32.0 (1.26) 27.0 (1.06) 5.948 ~ 5.963 (0.2342 ~ 0.2348) 5.940 ~ 5.955 (0.2339 ~ 0.2344) 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) 0.01 (0.0004) 90∞

←

6.000 ~ 6.012 (0.2362 ~ 0.2367) 6.000 ~ 6.012 (0.2362 ~ 0.2367) 0.037 ~ 0.064 (0.00146 ~ 0.00252) 0.045 ~ 0.072 (0.00177 ~ 0.00283) 0.08 ~ 0.12 (0.0031 ~ 0.0047) 0.08 ~ 0.12 (0.0031 ~ 0.0047)

EX

Valve clearance

YG5200D

mm (in) IN EX IN

← ← ← ← ←

← ← ← ← ← ← ← ← ← ←

0.5 (0.02)

← ←

36.2 (1.4252) 36.2 (1.4252) 34.0 (1.34) 34.0 (1.34) 29.0 (1.1417) 29.0 (1.1417) 10 kg (22.0 lb) 10 kg (22.0 lb) 1.6 (0.06)

← ← ← ← ← ← ← ← ←

mm (in) mm (in) IN EX IN EX IN EX IN EX

Tilt limit

10

3-67

SPEC

Yamaha Generator Theory & Diagnostics Guide MAINTENANCE SPECIFICATIONS

Unit Carburetor: Type/manufacture I.D. mark Bore size Main jet Main air jet Pilot air jet Pilot outlet Valve seat size Main nozzle Pilot jet Throttle valve Float height ìHî Carburetor heater resistance

EF5200DE

SPEC YG5200D

mm (in) BV26-18/MIKUNI 7RG20 ¯ 18 #98.8 ¯ 1.6 (0.063) ¯ 0.9 (0.035) ¯ 1.0 (0.039) ¯ 2.0 (0.079) 53A #62.5 #120 14.8 (0.58) 26 at 23 ∞C (73 ∞F)

(Ω ± 10%)

← 7RT30 ← ← ← ← ← ← ← ← ← 14.3 (0.56) −

GENERATOR Unit

EF5200DE

YG5200D

Generator: Main coil AC voltage (with the sub coil coupler connected) 120 V (Br-R) V 240 V (Br-L) V Main coil AC voltage (with the sub coil coupler disconnected) 120 V (Br-R) V 240 V (Br-L) V Sub coil AC voltage (with the sub coil coupler disconnected) 120/240 V (G-G) V Exciter field coil voltage V Coil resistance Main coil (Br-R) (Ω ± 10%) (Br-L) (Ω ± 10%) Field coil (rotor assembly) (Ω ± 10%) Sub coil (G-G) (Ω ± 10%) Exciter field coil (Ω ± 10%) Exciter armature coil (Ω ± 10%)

130 ~ 140 225 ~ 275

← ←

20 ~ 30 40 ~ 60

← ←

5~6 14

← ←

0.17 0.47 30 0.28 4.5 1.6

← ← ← ← ← ←

11

3-68

Current Model Specifications and Wiring Diagrams – EF5200DE

MAINTENANCE SPECIFICATIONS

SPEC

ELECTRICAL Unit

EF5200DE

Electrical: Ignition system Ignition timing at 3,600 r/min Primary coil resistance (Ω ± 20%) Secondary coil resistance (kΩ ± 10%) Spark plug cap resistance (kΩ) Air gap between TCI unit and flywheel mm (in) Minimum spark gap mm (in) Charging coil resistance (battery charging) W-Ground (Ω ± 20%) G/R-Ground (Ω ± 20%) Economy idle system Economy idle voltage (DC) (economy idle unit) V Solenoid valve voltage (DC) V Solenoid valve resistance (Ω ± 10%) Electric starting system Depth of insulator mm (in) Insulation resistance Wear limit length Starter relay coil resistance Battery Capacity

(MΩ) mm (in) (Ω ± 20%)

YG5200D

BTDC 25 ± 3∞ 1.2 11.7 4.0 ~ 6.0

← ← ← ←

0.4 ~ 0.6 (0.0157 ~ 0.0236) 6 (0.24)

← ←

1.3 0.9

− −

10 ~ 17 8 ~ 10 35.5

← ← ←

0.4 ~ 0.8 (0.0157 ~ 0.0315) More than 1 8.5 (0.33) 3.4

− − − −

12 V-26 Ah

−

12

3-69

Yamaha Generator Theory & Diagnostics Guide WIRE ROUTING DIAGRAM

SPEC

WIRE ROUTING DIAGRAM CONTROL BOX PANEL AND BEHIND CONTROL BOX (EF5200DE)

ECON. SW ON

EF5200DE

AC SW

20A

OHV ENGINE BRUSHLESS OIL WARNING

OFF

È Condenser É Negative side is indicated in black. Ê Economy idle unit Ë Pass the longer brown lead through the economy idle unit coil.

30A

ON

ON

OFF

OFF

ON STOP

START

120V 120V

120/240V

AC

240V

PVX0110

COLOR CODE B ............Black Br ...........Brown L.............Blue R ............Red Y ............Yellow B/W........Black/White G/Y ........Green/Yellow

G/Y

A B

A

B Y B/W W Y R B/W

R

Br

L

R

R

Br

L

Br

Br

G/Y L Y

Br

Y

G/Y

G/Y

Br

PVX0120

Y

G

PVX0130

14

3-70

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF6300iSDE

INVERTER GENERATOR EF6300iSDE

3-71

Yamaha Generator Theory & Diagnostics Guide EF6300iSDE WIRING DIAGRAM

3-72

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF6300iSDE

3-73

Yamaha Generator Theory & Diagnostics Guide

3-74

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF6300iSDE

3-75

Yamaha Generator Theory & Diagnostics Guide

3-76

ELEC

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF6600DE

ELECTRICAL COMPONENTS AND CIRCUIT DIAGRAM CONVENTIONAL GENERATOR EF6600DE

ELECTRICAL

ELECTRICAL COMPONENTS AND CIRCUIT DIAGRAM EF6600DE 1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a s d f g h j

Main switch Economy idle switch Oil warning light Voltage meter AC switch (120 V-20 A, NFB) AC receptacle (125 V-20 A) AC switch (120 V-30 A, NFB) AC receptacle (125 V-30 A) AC receptacle (125/250 V-30 A) AC switch (120 V, NFB) AC switch (240 V, NFB) Exciter stator assembly Stator assembly Rotor assembly Oil level switch Spark plug TCI unit Resistor Oil warning unit Rectifier AVR i Condenser Economy idle unit Ground terminal Fuse (10 A) Rectifier/regulator Solenoid valve

f

34 5 6789 0 q

2 1

wer

t

y

u

o

a

p

h

s

j

Y G

3-77 8

d

g

f

1 2 3 4 5 6 7 8 9 0 q

3-78 9

x

c

z

2

3

4

;

l

j

1

k

5

Rotor assembly Exciter coil Sub coil Main coil Stator assembly Voltage meter NFB AC receptacle (125 V-20 A) AC receptacle (125 V-30 A) AC receptacle (125/250 V-30 A) Ground terminal

B

EF6600DE

B W

120V

f

d

240V

Y

Y

Y

G

R

R

Engine switch Rectifier Remote control terminal Fuse (10 A) Rectifier/regulator Voltage adjuster Condenser AVR Oil warning unit Oil warning light Economy idle unit

h

w e r t y u i o p a s

M

g

B W

Y GG

L B/W R/W W G/R G/R B L/R L/W R

Y G G

Br

R

L

G/Y

Br

R

s B W W G B Y R G

d f g h j k l ; z x c

B W W G B Y R G

R

L G R

i

p

o

Br

L Y B/W B

7

G/Y

W R B

R

R

r

B

7

Br

B

G/R L/W B Y

B

L

G/Y

w

B/W

R

R/W

L/R

e

Y

Color code B ..........Black Br .........Brown G ..........Green Gy ........Gray L...........Blue R ..........Red W .........White B/W ......Black/White G/R ......Green/White G/Y.......Green/Yellow L/W ......Blue/White R/W......Red/White Y ..........Yellow

G/R L/W B Y

R Y B/W R/W L/R

B B/W B/W B R R/W R/W R L/R Y Y L/R

B

B B/W R R/W L/R Y

0

OFF ON START

q

G/Y R

B G/R G/R B L/W Y Y L/W

R/W B B/W R/B G/R

B R/B G/R B/W R/W B

G/Y R

t

Br

u y

G/R R B W G/R

Br

8 9 7

Economy idle solenoid valve Economy idle switch Starter relay Starter motor Auto choke coil Fuel cut solenoid valve Battery Charging coil T.C.I.unit Spark plug Oil level switch

B/W Y

B/W Y

a

6 7

G Y L/W G Y L/W

V

L

Yamaha Generator Theory & Diagnostics Guide ELEC ELECTRICAL COMPONENTS AND CIRCUIT DIAGRAM

EF6600DE WIRING DIAGRAM

SPEC – EF6600DE GENERAL SPECIFICATIONS Current Model Specifications and Wiring Diagrams SPECIFICATIONS GENERAL SPECIFICATIONS Unit Model code number Dimensions: Overall length Overall width Overall height Dry weight Noise level: Engine: Engine type Cylinder arrangement Displacement Bore × Stroke Compression ratio Operating hours Fuel Fuel tank capacity Engine oil capacity Engine oil grade

EF6600DE 7CCB mm (in) mm (in) mm (in) kg (lb) dB(A)/Hzl

L (cm3) mm (in) 60 Hz · Hrs L (Imp gal, US gal) L (Imp qt, US qt)

894 (35.2) 520 (20.5) 527 (20.7) 91 (200.6) 74/60

YG6600D

670 (26.4) 510 (20.1) 577 (22.7) 86 (189.6)

YG6600DE

894 (35.2) 520 (20.5) 93 (205.0)

4-stroke OHV forced air cooled 1 0.357 (357) 85.0 × 63.0 (3.35 × 2.48) 8.1 : 1 6.8 Unleaded regular gasoline 23.0 (5.06, 6.08) 1.1 (0.97, 1.16) 4-stroke engine oil API service classification SE or SF, if not available, SD

(5W-30)

Lubrication system Air filter system Cooling system Ignition system Starting system Stopping system Rotating direction Governor type Electrical: Ignition system Spark plug type Gap

Forced splashing Semi-wet (Urethane foam) Forced air cooling TCI Electric and Recoil starter recoil starter Misfire Clockwise (from flywheel) Centrifugal weight system

mm (in)

BPR4ES (NGK) 0.7 ~ 0.8 (0.028 ~ 0.031)

20

3-79

Electric and recoil starter

Yamaha Generator Theory & Diagnostics Guide SPEC GENERAL SPECIFICATIONS

Unit

EF6600DE

Generator: Type Number of phase Number of poles Excitation Initial excitation Driving method Rated power factor Frequency variation Voltage fluctuation AC output Rated voltage Frequency Rated output Rated current Safety device type Rated engine speed Economy idle engine speed Voltage regulation Insulation resistance Insulation class Stator Rotor Receptacle AC

YG6600D

YG6600DE

Brushless, self-exciting, single-phase, synchronous generator Single phase 2 Self magnetization Residual magnetization Direct connection 1 Less than 5% Less than 10% V Hz kVA A r/min r/min MΩ

120/240 60 6.0 50.0/25.0 NFB (No Fuse Breaker) 3,600 2,350 AVR More than 10 E class B class 20 A (125 V) (Duple) × 1, 30 A (125 V) × 1, 30 A (250/125 V) × 1

3-80

21

20 A (125 V) (Duple) × 2, 30 A (125 V) × 1, 30 A (250/125 V) ×1

Current Model Specifications and Wiring Diagrams – EF6600DE MAINTENANCE SPECIFICATIONS SPEC

MAINTENANCE SPECIFICATIONS ENGINE Unit Piston: Piston clearance <Limit> Piston skirt “D” <Limit> Measuring point “H” Oversize

EF6600DE

YG6600D

YG6600DE

mm (in)

1st 2nd Piston pin hole inside diameter <Limit> Piston pin: mm (in) Piston pin diameter <Limit> Piston ring: mm (in) Top ring Type Dimensions “B × T” End gap <Limit> Side clearance <Limit> 2nd ring Type Dimensions “B × T” End gap <Limit> Side clearance <Limit> Oil ring B Type Dimensions “B × T” T End gap <Limit>

0.015 ~ 0.029 (0.0006 ~ 0.0011) 0.100 (0.0039) 84.977 ~ 84.998 (3.3456 ~ 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 (0.035) 0.04 ~ 0.08 (0.0016 ~ 0.0031) 0.1 (0.0039) Taper 1.5 × 3.6 (0.059 × 0.142) 0.20 ~ 0.35 (0.008 ~ 0.014) 0.9 (0.035) 0.03 ~ 0.07 (0.0012 ~ 0.0028) 0.1 (0.0039) 3-piece type 3.0 × 3.0 (0.118 × 0.118) 0.20 ~ 0.70 (0.008 ~ 0.028) 0.9 (0.035)

3-81

22

Yamaha Generator Theory & Diagnostics Guide SPEC MAINTENANCE SPECIFICATIONS

Unit Cylinder head: Warpage limit Cylinder: Inside diameter “D” <Limit> Taper limit Warpage limit Crankshaft: Big end side clearance “A” <Limit> Runout “B” <Limit> Crank pin outside diameter “C” <Limit> Connecting rod: Small end diameter “A” Oil clearance Big end diameter “B” Oil clearance <Limit> Camshaft: Camshaft outside diameter Cam dimension “A” IN <Limit> “A” EX <Limit> “B” IN <Limit> “B” EX <Limit> Camshaft journal diameter <Limit>

EF6600DE

YG6600D

YG6600DE

mm (in) 0.05 (0.0020) mm (in) 85.000 ~ 85.020 (3.3465 ~ 3.3472) 85.020 (3.3472) 0.05 (0.0020) 0.05 (0.0020) mm (in) 0.20 ~ 0.65 (0.008 ~ 0.026) 0.8 (0.031) 0.04 (0.0016) 35.969 ~ 35.984 (1.4161 ~ 1.4167) 35.9 (1.4134) mm (in) 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 (0.0039) mm (in)

32.55 ± 0.05 (1.281 ± 0.002) 32.40 (1.276) 32.55 ± 0.05 (1.281 ± 0.002) 32.40 (1.276) 26.08 ± 0.05 (1.027 ± 0.002) 25.93 (1.021) 26.08 ± 0.05 (1.027 ± 0.002) 25.93 (1.021) 15.965 ~ 15.990 (0.6285 ~ 0.6295) 15.950 (0.6280)

3-82 23

Current Model Specifications and Wiring Diagrams – EF6600DE

MAINTENANCE SPECIFICATIONS SPEC Unit Valve: Valve Face diameter “A” Stem diameter “B” <Limit> Stem length “C”

EF6600DE

YG6600D

YG6600DE

mm (in) IN EX IN EX IN EX IN EX

32.0 (1.26) 27.0 (1.06) 5.948 ~ 5.963 (0.2342 ~ 0.2348) 5.940 ~ 5.955 (0.2339 ~ 0.2344) 5.9 (0.2323) 5.9 (0.2323) 88.1 (3.47) 87.9 (3.46)

Valve face contact width “D”

IN EX <Limit> IN EX Valve seat contact width IN EX <Limit> IN EX Valve stem runout limit “θ” Valve guide Guide inside diameter IN EX Stem to guide clearance IN EX Valve clearance (cold) IN EX Push rod: Runout limit

0.7 ~ 0.9 (0.0276 ~ 0.0354) 0.7 ~ 0.9 (0.0276 ~ 0.0354) 1.4 (0.0551) 1.4 (0.0551) 0.7 ~ 0.9 (0.0276 ~ 0.0354) 0.7 ~ 0.9 (0.0276 ~ 0.0354) 1.4 (0.0551) 1.4 (0.0551) 0.01 (0.0004) 90° 6.000 ~ 6.012 (0.2362 ~ 0.2367) 6.000 ~ 6.012 (0.2362 ~ 0.2367) 0.037 ~ 0.064 (0.00146 ~ 0.00252) 0.045 ~ 0.072 (0.00177 ~ 0.00283) 0.08 ~ 0.12 (0.0031 ~ 0.0047) 0.08 ~ 0.12 (0.0031 ~ 0.0047) mm (in) 0.5 (0.02)

3-83

24

Yamaha Generator Theory & Diagnostics Guide

MAINTENANCE SPECIFICATIONS SPEC

Unit Valve spring: Free length

EF6600DE

YG6600D

YG6600DE

mm (in) IN EX IN EX IN EX IN EX

<Limit> Set length Set force Tilt limit Carburetor: Type/manufacture

36.2 (1.43) 36.2 (1.43) 34.0 (1.34) 34.0 (1.34) 29.0 (1.14) 29.0 (1.14) 10 kg (22.0 lb) 10 kg (22.0 lb) 1.6 (0.06) mm (in) BV26-20/ BV26-21/ MIKUNI MIKUNI 7CT70 7CT20 ø20 ø21 #116.3 #98.8 ø1.4 ø1.6 ø0.9 ø0.9 ø1.0 ø1.8 ø2.0 106 P 53 A #50 #63.8 #120 14.9 (0.59) 26 Ω at 23 °C (73.4 °F)

I.D. mark Bore size Main jet Main air jet Pilot air jet Pilot outlet Valve seat size Main nozzle Pilot jet Throttle valve Float height “H” Carburetor heater resistance

BV26-20/ MIKUNI 7CT70 ø20 #116.3 ø1.4 ø0.9 ø1.8 106 P #50

GENERATOR Unit

EF6600DE

Generator: Type Main coil AC voltage (with the sub coil coupler connected) 120 V (Br-R) 240 V (Br-L) Main coil AC voltage (with the sub coil coupler disconnected) 120 V (Br-R) 240 V (Br-L) Sub coil AC voltage (with the sub coil coupler disconnected) 120/240 V (G-G) Exciter stator coil voltage

YG6600D

YG6600DE

Brushless, self-exciting, single-phase, synchronous generator

V V

114 ~ 140 225 ~ 275

V V

20 ~ 30 40 ~ 60

V V

4 ~ 12 10 ~ 20

3-84

25

Current Model Specifications and Wiring Diagrams – EF6600DE MAINTENANCE SPECIFICATIONS SPEC

Unit Coil resistance Main coil (Br-R) (Br-L) Field coil (rotor assembly) Sub coil (G-G) Exciter stator coil Exciter rotor coil

EF6600DE (Ω ± 10%) (Ω ± 10%) (Ω ± 10%) (Ω ± 10%) (Ω ± 10%) (Ω ± 10%)

YG6600D

YG6600DE

YG6600D

YG6600DE

0.16 0.45 28 0.35 45 1.7

ELECTRICAL Unit Electrical: Ignition system Ignition timing at 3,600 r/min Spark plug type Gap Primary coil resistance (Ω ± 20%) Secondary coil resistance (KΩ ± 20%) Spark plug cap resistance (KΩ) Air gap between TCI unit and flywheel mm (in) Minimum spark gap mm (in) Charging coil resistance (battery charging) W-Ground (Ω ± 20%) G/R-Ground (Ω ± 20%) Economy idle system Economy idle voltage (DC) (economy idle unit) V Economy idle solenoid valve voltage (DC) V Economy idle solenoid valve resistance (Ω ± 10%) Electric starting system Depth of insulator mm (in)

Brush spring pressure Insulation resistance Wear limit length Holding coil resistance å-∫ Pull-in coil resistance å-ç Battery Capacity

N (Kgf, lbf) (MΩ) mm (in) (Ω ± 20%) (Ω ± 20%)

EF6600DE

BTDC 23° ± 3° BPR4ES (NGK) 0.7 ~ 0.8 (0.028 ~ 0.031) 0.6 12 3.0 ~ 7.5 0.5 (0.020) 6 (0.24) 2.3 1.7

— 1.1

2.3 1.7

— —

10 ~ 18 10 ~ 18 35.5 0.4 ~ 0.8 (0.0157 ~ 0.0315) 13 (1.325, 2.91) More than 0.1 6 (0.24) 1.1 0.5

— — — —

0.4 ~ 0.8 (0.0157 ~ 0.0315) 13 (1.325, 2.91) More than 0.1 6 (0.24) 1.1 0.5

12 V-26 Ah

—

12 V-26 Ah

3-85

26

—

Yamaha Generator Theory & Diagnostics Guide SPEC WIRE ROUTING DIAGRAM

WIRE ROUTING DIAGRAM CONTROL BOX PANEL AND BEHIND CONTROL BOX EF6600DE å Condenser ∫ Negative side is indicated in black. ç Economy idle unit

COLOR CODE B ......... Black Br ........ Brown L .......... Blue R ......... Red Y ......... Yellow B/W ..... Black/White G/Y ...... Green/Yellow

∂ Pass the longer brown lead through the economy idle unit coil.

A G/Y B

A å B/W Y

Y B/W

Br

Br

∂

ç

R

R

R Br G/Y

L L

R

G/Y

Br

Br

L

å

Br Br

Br Y Y

Br

R Br

G/Y

Br

Y G

29 3-86

B

∫

W

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF12000DE CONTROL PANEL

SERVICE DATA Clearance Data and Limits EF12000DE

3-87

Yamaha Generator Theory & Diagnostics Guide EF12000DE

3-88

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF12000DE

EF12000DE

3-89

Yamaha Generator Theory & Diagnostics Guide EF12000DE

3-90

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF12000DE

EF12000DE

3-91

Yamaha Generator Theory & Diagnostics Guide EF12000DE

3-92

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF12000DE

EF12000DE

3-93

Yamaha Generator Theory & Diagnostics Guide CONVENTIONAL GENERATOR EF12000DE Control Box

3-94

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; EF1200DE EF12000DE WIRING DIAGRAM

3-95

Yamaha Generator Theory & Diagnostics Guide INDUSTRIAL SERIES GENERATORS ELECTRICAL COMPONENTS

ELEC

â&#x20AC;&#x201C;

+

YG2800i ELECTRICAL ELECTRICAL COMPONENTS 1 Control unit 2 Engine switch 3 Economy switch 4 Oil warning unit 5 AC receptacle (20 A, GFCI) 6 AC receptacle (30 A) 7 Ground terminal 8 Overload warning 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 unit I Ignition coil J DC receptacle (12 V-10 A) K Rectifier

PVU0080

PVU0090

8

J

12V10A

BATTERY CHARGE ONLY

AC

9

6

5

DC

ECON. SW

0

7

OVER LOAD

20A

TO RESET AC RESTART ENJINE

GFCI

3

2

RESET

OFF DC PROTECTOR

B

AC~

4

PVU0100

5

3-96

6

3-97

K

J

3

2

0

1

B/W

G/Y

G Y R L Or

L L

G Y R L Or

R Or Or R

G/Y Or Or G/Y

L L

CIRCUIT DIAGRAM

Y

Or Or R G/Y

L

Y Y Y Y

Y

BR

G/Y G/Y B/W

R Y Y W B

Y

I

5

W/L

B

H

G/Y W/L B/W

G/Y W/L B/W

R G/Y B/W

R G/Y B/W

4

G

R

R

F

R B Y B/W Or Or

R Y L B/W

B/W

R R

L

B

B/W

Y

B

R

Y

R B

Y

6

D

C

N

M

B

A

7 G/Y

E

R

Br

COLOR CODE B ............Black Br ...........Brown G............Green Gy ..........Gray L.............Blue Or...........Orange R ............Red

R

Br

9

PVU0110

9

R G/Y R

G/Y

8

W ...........White Y ............Yellow B/W ........Black/White G/Y.........Green/Yellow W/L ........White/Blue

Br

N DC circuit breaker

(12 V-10 A)

H Ignition coil I AC-CDI unit J Pulser coil K Throttle control motor L Rectifier M DC receptacle

CIRCUIT DIAGRAM

B

L

B R R B Gy Y Y B/W Br Or Or Or

R Br R R

9 Ground terminal 0 DC charge coil A Economy switch B Overload warning light (ignition source) 4 Generator assembly C Engine switch 5 Control unit D Oil warning light 6 Pilot light E Oil warning unit 7 AC receptacle (20 A, GFCI) F Oil level switch 8 AC receptacle (30 A) G Spark plug

1 Main coil 2 Sub coil (AC control) 3 Charge coil

Current Model Specifications and Wiring Diagrams – YG2800i

ELEC

–

+

YG2800i WIRING DIAGRAM

SPEC

GENERAL SPECIFICATIONS Yamaha Generator Theory & Diagnostics Guide

SPECIFICATIONS

GENERAL SPECIFICATIONS Unit

YG2800i

Model code number Dimensions: Overall length mm (in) Overall width mm (in) Overall height mm (in) Dry weight kg (lb) Engine: Engine type Cylinder arrangement Displacement L (cm3) Bore × Stroke mm (in) Compression ratio Rated output 60 Hz · kW (PS)/3,600 r/min Rated engine speed r/min Operating hours 60 Hz · Hrs W/no load W/rated load Fuel Fuel tank capacity L (Imp gal, US gal) Engine oil capacity L (Imp qt, US qt) Engine oil grade

7VU2 487 (19.2) 395 (15.6) 425 (16.7) 29 (63.9) 4-stroke OHV forced air cooled 1 0.171 (171) 66.0 × 50.0 (2.60 × 1.97) 8.5:1 3.3 (4.4) 3,550 24.9 7.7 Unleaded regular gasoline 11.2 (2.46, 2.96) 0.6 (0.53, 0.63) 4-stroke engine oil API service classification SE or SF, if not available, SD

(5W-30)

Electrical: Ignition system Ignition timing Spark plug type Gap Generator: Type Initial excitation Driving method Rated power factor Frequency variation Instantaneous Settling Settling time

AC-CDI (Voltage) BTDC 23 ± 1° BPR4ES (NGK) 0.7 ~ 0.8 (0.028 ~ 0.031)

mm (in)

Multi pole rotating field magnet Permanent magnet Direct connection 1 Less than 1% Less than 0.1% Less than 1 sec 7

3-98

Current Model Specifications and Wiring Diagrams – YG2800i

GENERAL SPECIFICATIONS Unit Voltage fluctuation Instantaneous Settling Settling time AC output Rated voltage Frequency Rated output Rated current Safety device type Rated engine speed Voltage regulation Voltage stability Frequency stability Rotating speed control Wave distortion ratio Number of phase Insulation resistance Insulation type Receptacle

SPEC

YG2800i Less than 20% Less than 3% Less than 3 sec V Hz kVA A AC DC r/min

120 60 2.5 20.8 Electronic no fuse breaker Circuit breaker (No fuse breaker) 3,550 Voltage feed back system Within ± 1% Within ± 0.1 Throttle motor control type Less than 2.5% Single phase Over 10 E type 20 A (Duples) × 1, 30 A × 1 10 A × 1

Hz

MΩ AC DC

8

3-99

Yamaha Generator Theory & Diagnostics Guide MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS Unit Piston: Piston clearance <Limit> Piston skirt “D” <Limit> Measuring point “H” Oversize 1st 2nd Piston pin hole inside diameter <Limit> Piston pin: Piston pin diameter <Limit> Piston ring: Top ring Type Dimensions “B × T” End gap <Limit> Side clearance <Limit> 2nd ring Type Dimensions “B × T” End gap <Limit> Side clearance <Limit> Oil ring Type Dimensions “B × T” End gap <Limit> Cylinder head: Warpage limit Cylinder: Inside diameter “D” <Limit> Taper limit Warpage limit

YG2800i mm (in) 0.015 ~ 0.040 (0.00059 ~ 0.00157) 0.100 (0.0039) 66.0 (2.598) 65.9 (2.594) 10.0 (0.4) 66.25 (2.6083) 66.50 (2.6181) 16.002 ~ 16.013 (0.6300 ~ 0.6304) 16.020 (0.6307) mm (in) 15.995 ~ 16.000 (0.6297 ~ 0.6299) 15.950 (0.6280) mm (in) Barrel face 1.5 × 2.7 (0.059 × 0.106) 0.2 ~ 0.4 (0.008 ~ 0.016) 0.9 (0.0354) 0.04 ~ 0.08 (0.0016 ~ 0.0031) 0.1 (0.0039) Taper 1.5 × 2.7 (0.059 × 0.106) 0.2 ~ 0.4 (0.008 ~ 0.016) 0.9 (0.0354) 0.02 ~ 0.06 (0.0008 ~ 0.0024) 0.1 (0.0039) Solid 2.5 × 2.7 (0.098 × 0.106) 0.2 ~ 0.4 (0.008 ~ 0.016) 0.9 (0.0354) mm (in) 0.05 (0.002) mm (in) 66.00 ~ 66.02 (2.5984 ~ 2.5990) 66.020 (2.5990) 0.05 (0.002) 0.05 (0.002)

9

3-100

Current Model Specifications and Wiring Diagrams – YG2800i

MAINTENANCE SPECIFICATIONS Unit

YG2800i

Crankshaft: Big end side clearance “A” <Limit> Runout “B” <Limit> Crank pin diameter “C” <Limit> Connecting rod: Small end diameter “A” Oil clearance Big end diameter “B” Oil clearance <Limit> Camshaft: Camshaft outside diameter Cam dimension “A”

mm (in) 0.20 ~ 0.60 (0.008 ~ 0.024) 0.75 (0.029) 0.04 (0.0016) 28.0 (1.102) 27.9 (1.098) mm (in) 16.006 ~ 16.020 (0.6301 ~ 0.6307) 0.006 ~ 0.025 (0.0002 ~ 0.0010) 28.000 ~ 28.015 (1.1023 ~ 1.1029) 0.015 ~ 0.040 (0.0006 ~ 0.0016) 0.1 (0.004) mm (in) IN EX 26.9 ± 0.05 26.68 ± 0.05 (1.06 ± 0.002) (1.05 ± 0.002) 26.75 (1.053) 26.53 (1.044) 22.0 ±0.05 22.03 ± 0.05 (0.87 ± 0.002) (0.87 ± 0.002) 21.85 (0.860) 21.88 (0.861) 14.965 ~ 14.990 (0.5892 ~ 0.5902) 14.950 (0.59)

<Limit> “B” <Limit> Camshaft journal <Limit> Valve: Valve Face diameter “A” Stem diameter “B” <Limit> Stem lengtlh “C” Valve face contanct width “D”

SPEC

mm (in) IN EX IN EX IN EX IN EX

24.0 (0.94) 22.0 (0.87) 5.5 (0.22) 5.5 (0.22) 5.4 (0.21) 5.4 (0.21) 65.9 (2.59) 66.2 (2.61)

IN EX

0.7 (0.03) 0.7 (0.03) 1.7 (0.067) 0.01 (0.0004) 90°

<Limit> Valve stem runout limit “θ”

10

3-101

Yamaha Generator Theory & Diagnostics Guide MAINTENANCE SPECIFICATIONS

Unit Valve guide Guide inside diameter

IN EX <Limit> IN EX Stem to guide clearance IN EX Valve clearance IN EX Push rod: Runout limit Valve spring: Free length IN EX <Limit> IN EX Set length IN EX Set force IN EX Tilt limit Carburetor: Type/manufacture I.D. mark Bore size Main jet Min air jet Pilot air jet Pilot outlet Valve seat size Main nozzle Pilot jet Throttle valve Float height “H”

SPEC

YG2800i mm (in) 5.5 (0.22) 5.5 (0.22) 5.4 (0.21) 5.4 (0.21) 0.04 ~ 0.06 (0.0016 ~ 0.0020) 0.06 ~ 0.08 (0.002 ~ 0.003) 0.1 (0.004) 0.1 (0.004) mm (in) 0.5 (0.02) mm (in) 26.5 (1.04) 26.5 (1.04) 25.0 (0.98) 25.0 (0.98) 21.6 (0.85) 21.6 (0.85) 4.5 kg (9.9 lb) 4.5 kg (9.9 lb) 1.6 (0.06) mm (in) BV20-15/MIKUNI 7VU 10 ø15 #88.8 ø1.8 (0.0709) ø1.1 (0.0433) ø0.9 (0.0354) ø1.8 (0.0709) 31B #37.5 #150 16.0 (0.63)

11

3-102

Current Model Specifications and Wiring Diagrams – YG2800i

MAINTENANCE SPECIFICATIONS Unit

YG2800i

Generator: Main coil AC voltage (3 phase) (V/r/min) (With the throttle control motor coupler disconnected) Sub coil AC voltage (single phase) (V/r/min) (With the throttle control motor coupler disconnected) Coil resistance Main coil (Ω ± 10%) Sub coil (Ω ± 10%) DC charge coil (Ω ± 10%) Electrical: Ignition system Pulser coil resistance (Ω ± 20%) Ignition timing at 3,800 r/min Primary coil resistance (Ω ± 15%) Secondary coil resistance (kΩ ± 20%) Charge coil resistance (Ω ± 10%) (ignition source) Spark plug cap resistance (kΩ) Minimum spark gap mm (in)

130 ~ 160/2,800

13.5 ~ 23.0/2,800

0.6 (Yellow-Yellow) 0.14 (Orange-Orange) 0.5 (Blue-Blue) AC-CDI (voltage) 185 BTDC 23° 0.11 6.7 0.5 4.0 ~ 6.0 6 (0.24)

12

3-103

SPEC

Yamaha Generator Theory & Diagnostics Guide CONVENTIONAL GENERATOR YG4000D

3-104

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; YG4000D

3-105

Yamaha Generator Theory & Diagnostics Guide YG4000D WIRING DIAGRAM

3-106

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; YG4000D

3-107

Yamaha Generator Theory & Diagnostics Guide

(5W-30)

3-108

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; YG4000D

3-109

Yamaha Generator Theory & Diagnostics Guide

3-110

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; YG4000D

3-111

Yamaha Generator Theory & Diagnostics Guide

3-112

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; YG4000D

3-113

Yamaha Generator Theory & Diagnostics Guide

3-114

Current Model Specifications and Wiring Diagrams – YG4000D

ELECTRICAL COMPONENTS CONVENTIONAL GENERATOR YG5200D

ELEC

ñ

+

YG5200D 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N

Engine switch Economy switch Oil warning light Voltage meter AC switch (120 V-20 A, NFB) AC receptacle (125 V-20 A, GFCI) AC receptacle (125 V-20 A) AC receptacle (125 V-30 A) AC receptacle (125/250 V-20 A) AC switch (120 V, NFB) AC switch (240 V, NFB) Exciter field coil Stator assembly Rotor assembly Oil level switch Spark plug TCI unit Oil warning unit Rectifier AVR Condenser Economy idle unit Ground terminal Solenoid valve

PVX0060

PVX0070

Y

G

PVX0080

3

3-115

L

G

YG5200D

G/R

B/W

G/Y

B W

Y G G B W

Br

Br

B W

R

R

B W

Y G G

L

L

Y Y G G G G

1 2 3 4 5 6 7

COLOR CODE B ............ Black Br........... Brown G............ Green

5

3-116

120V

240V

Rotor assembly Stator assembly Main coil Sub coil Exciter field coil Voltage meter AC switch (NFB)

G/R

L B/W

Y

Y

R Br

B W W G B Y R G

B/W

B/W

V

Y

Y

B W W G B Y R G

G/Y

L Y B/W B

Br

R

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-20 A)

G Y L/W

G Y L/W

R Br

L

B C D E F G H

Br

R

Br

R

G/R L/W B Y

G/Y

B/W

B

R

B G/R G/R B L/W Y Y L/W

B

Br

G/Y

G/R L/W B Y

L

I J K L M N O

G/Y

Oil warning light Solenoid valve Economy switch Oil level switch Charging coil TCI unit Spark plug

R/B ........ Red/Black R/W ....... Red/White

CIRCUIT DIAGRAM

Ground terminal Engine switch Rectifier AVR Condenser Economy idle unit Oil warning unit

G/Y

B/W ........Black/White G/Y ........Green/Yellow G/R ........Green/Red L/W ........Blue/White

YG5200D WIRING DIAGRAM

Y

G

R

L ............ Blue R ........... Red W........... White Y............ Yellow

Yamaha Generator Theory & Diagnostics Guide ELEC

ñ

PVX0100

+

SPEC GENERAL SPECIFICATIONS Current Model Specifications and Wiring Diagrams – YG5200D SPECIFICATIONS GENERAL SPECIFICATIONS Unit

EF5200DE

Model code number Dimensions: Overall length Overall width Overall height Dry weight Engine: Engine type

mm (in) mm (in) mm (in) kg (lb)

Cylinder arrangement Displacement Bore × Stroke

7VX2

←

894 (35.2) 520 (20.5) 510 (20.1) 87 (191.4)

670 (26.4) 510 (20.1) 560 (22.0) 83 (182.6)

← 4-stroke OHV forced air cooled ← 1 ← 0.301 (301) ← 78.0 × 63.0 (3.07 × 2.48) ← 8.1 : 1 ← 5.8 (7.9) ← 7.6 Unleaded regular gas- ← oline ← 21.0 (4.62, 5.55) ← 1.1 (0.97, 1.16) 4-stroke engine oil API service classification SE or SF, if not available, SD

L (cm3) mm (in)

Compression ratio Rated output 60 Hz ∑kW (PS)/3,600 r/min Operating hours 60 Hz ∑Hrs Fuel Fuel tank capacity Engine oil capacity Engine oil grade

YG5200D

L (Imp gal, US gal) L (Imp qt, US qt)

(5W-30)

Electrical: Ignition system Ignition timing at 3,600 r/min Spark plug type Gap

TCI BTDC 25 ± 3∞ BPR4ES (NGK) 0.7 ~ 0.8 (0.028 ~ 0.031)

mm (in)

6

3-117

← ← ← ←

Yamaha Generator Theory & Diagnostics Guide GENERAL SPECIFICATIONS Unit

EF5200DE

Generator: Type

Number of phase Number of poles Excitation Initial excitation Driving method Rated power factor Frequency variation Voltage fluctuation AC output Rated voltage Frequency Rated output Rated current Safety device type Rated engine speed Economy idle engine speed Voltage regulation Insulation resistance Insulation class Stator Rotor Receptacle AC

V Hz kVA A r/min r/min MΩ

YG5200D

Brushless, self-exciting, single-phase, synchronous generator Single phase 2 Self magnetization Residual magnetization Direct connection 1.0 Less than 5% Less than 10%

←

120/240 60 4.5 37.5/18.8 NFB (No fuse breaker) 3,600 2,350 AVR 10

← ← ← ← ← ← ← ← ←

E class B class

← ←

20 A (125 V) × 2, 30 A (125 V) × 1, 20 A (250/125 V) × 1

←

7

3-118

SPEC

← ← ← ← ← ← ← ←

Current Model Specifications and Wiring Diagrams – YG5200D

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS ENGINE Unit Piston: Piston clearance

EF5200DE mm (in) 0.024 ~ 0.038 (0.00094 ~ 0.00150) 0.100 (0.0039) 77.960 ~ 77.980 (3.0693 ~ 3.0701) 77.900 (3.067) 10.0 (0.4) 78.25 (3.0807) 78.50 (3.0906) 20.000 (0.7874) 20.020 (0.7882)

<Limit> Piston skirt ìDî <Limit> Measuring point ìHî Oversize 1st 2nd Piston pin hole inside diameter <Limit> Piston pin: Piston pin diameter <Limit> Piston ring: Top ring Type Dimensions ìB × Tî

YG5200D ← ← ← ← ← ← ← ← ←

mm (in) 19.995 ~ 20.000 (0.7872 ~ 0.7874) 19.950 (0.7854)

← ←

mm (in) Barrel face 1.5 × 3.5 (0.059 × 0.138) 0.2 ~ 0.4 (0.008 ~ 0.016) 0.9 (0.0354) 0.04 ~ 0.08 (0.0016 ~ 0.0031) 0.1 (0.0039)

End gap <Limit> Side clearance <Limit> 2nd ring Type Dimensions ìB × Tî

Taper 1.5 × 3.5 (0.059 × 0.138) 0.2 ~ 0.4 (0.008 ~ 0.016) 0.9 (0.0354) 0.03 ~ 0.07 (0.0012 ~ 0.0028) 0.1 (0.0039)

End gap <Limit> Side clearance <Limit> Oil ring Type Dimensions ìB × Tî

3-piece type 2.5 × 2.8 (0.098 × 0.110) 0.2 ~ 0.7 (0.008 ~ 0.028) 0.9 (0.0354)

End gap <Limit> 8

3-119

← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

Yamaha Generator Theory & Diagnostics Guide MAINTENANCE SPECIFICATIONS SPEC Unit Valve: Valve Face diameter ìAî Stem diameter ìBî

EF5200DE mm (in) IN EX IN EX

<Limit> Stem length ìCî Valve face contact width ìDî

IN EX IN EX IN EX

<Limit> Valve stem runout limit ìθî Valve guide Guide inside diameter IN

Stem to guide clearance IN EX IN EX Push rod: Runout limit Valve spring: Free length <Limit> Set length Set force

32.0 (1.26) 27.0 (1.06) 5.948 ~ 5.963 (0.2342 ~ 0.2348) 5.940 ~ 5.955 (0.2339 ~ 0.2344) 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) 0.01 (0.0004) 90∞

←

6.000 ~ 6.012 (0.2362 ~ 0.2367) 6.000 ~ 6.012 (0.2362 ~ 0.2367) 0.037 ~ 0.064 (0.00146 ~ 0.00252) 0.045 ~ 0.072 (0.00177 ~ 0.00283) 0.08 ~ 0.12 (0.0031 ~ 0.0047) 0.08 ~ 0.12 (0.0031 ~ 0.0047)

EX

Valve clearance

YG5200D

← ← ← ← ←

← ← ← ← ← ← ← ← ← ←

0.5 (0.02)

← ←

36.2 (1.4252) 36.2 (1.4252) 34.0 (1.34) 34.0 (1.34) 29.0 (1.1417) 29.0 (1.1417) 10 kg (22.0 lb) 10 kg (22.0 lb) 1.6 (0.06)

← ← ← ← ← ← ← ← ←

mm (in) mm (in) IN EX IN EX IN EX IN EX

Tilt limit

10

3-120

Current Model Specifications and Wiring Diagrams – YG5200D

MAINTENANCE SPECIFICATIONS Unit Carburetor: Type/manufacture I.D. mark Bore size Main jet Main air jet Pilot air jet Pilot outlet Valve seat size Main nozzle Pilot jet Throttle valve Float height ìHî Carburetor heater resistance

EF5200DE

SPEC

YG5200D

mm (in) BV26-18/MIKUNI 7RG20 ¯ 18 #98.8 ¯ 1.6 (0.063) ¯ 0.9 (0.035) ¯ 1.0 (0.039) ¯ 2.0 (0.079) 53A #62.5 #120 14.8 (0.58) 26 at 23 ∞C (73 ∞F)

(Ω ± 10%)

← 7RT30 ← ← ← ← ← ← ← ← ← 14.3 (0.56) −

GENERATOR Unit

EF5200DE

YG5200D

Generator: Main coil AC voltage (with the sub coil coupler connected) 120 V (Br-R) V 240 V (Br-L) V Main coil AC voltage (with the sub coil coupler disconnected) 120 V (Br-R) V 240 V (Br-L) V Sub coil AC voltage (with the sub coil coupler disconnected) 120/240 V (G-G) V Exciter field coil voltage V Coil resistance Main coil (Br-R) (Ω ± 10%) (Br-L) (Ω ± 10%) Field coil (rotor assembly) (Ω ± 10%) Sub coil (G-G) (Ω ± 10%) Exciter field coil (Ω ± 10%) Exciter armature coil (Ω ± 10%)

130 ~ 140 225 ~ 275

← ←

20 ~ 30 40 ~ 60

← ←

5~6 14

← ←

0.17 0.47 30 0.28 4.5 1.6

← ← ← ← ← ←

11

3-121

Yamaha Generator Theory & Diagnostics Guide MAINTENANCE SPECIFICATIONS

SPEC

ELECTRICAL Unit

EF5200DE

Electrical: Ignition system Ignition timing at 3,600 r/min Primary coil resistance (Ω ± 20%) Secondary coil resistance (kΩ ± 10%) Spark plug cap resistance (kΩ) Air gap between TCI unit and flywheel mm (in) Minimum spark gap mm (in) Charging coil resistance (battery charging) W-Ground (Ω ± 20%) G/R-Ground (Ω ± 20%) Economy idle system Economy idle voltage (DC) (economy idle unit) V Solenoid valve voltage (DC) V Solenoid valve resistance (Ω ± 10%) Electric starting system Depth of insulator mm (in) Insulation resistance Wear limit length Starter relay coil resistance Battery Capacity

(MΩ) mm (in) (Ω ± 20%)

YG5200D

BTDC 25 ± 3∞ 1.2 11.7 4.0 ~ 6.0

← ← ← ←

0.4 ~ 0.6 (0.0157 ~ 0.0236) 6 (0.24)

← ←

1.3 0.9

− −

10 ~ 17 8 ~ 10 35.5

← ← ←

0.4 ~ 0.8 (0.0157 ~ 0.0315) More than 1 8.5 (0.33) 3.4

− − − −

12 V-26 Ah

−

12

3-122

Current Model Specifications and Wiring Diagrams – YG5200D

WIRE ROUTING DIAGRAM

SPEC

CONTROL BOX PANEL AND BEHIND CONTROL BOX (YG5200D)

ECON. SW ON

YG5200D

20A

OFF

AC SW

20A

OHV ENGINE BRUSHLESS OIL WARNING

OFF

È Condenser É Negative side is indicated in black. Ê Economy idle unit Ë Pass the longer brown lead through the economy idle unit coil. Ì Protector

30A

ON

ON

OFF

OFF

ON

ON

GFCI

120V 120V

STOP

120/240V

AC

240V

PVX0170

COLOR CODE B ............Black Br ...........Brown L.............Blue R ............Red Y ............Yellow B/W........Black/White G/Y ........Green/Yellow

G/Y

A B

A

B Y B/W

Br

B

G/Y Br

W

R

Br

Y

B/W

Br

Br R L

B/W

R

B

Br Br

Y

R

R

Y G/Y

L

Br

L Br

G/Y

Br

G/Y

Br

B PVX0180

Y

G

PVX0190

18

3-123

7CC-28197-11

08.2.8 10:44 AM

Page 10

Yamaha Generator Theory & Diagnostics Guide ELECTRICAL COMPONENTS AND CIRCUIT DIAGRAM CONVENTIONAL GENERATOR YG6600D

ELEC

YG6600D 1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a s d f g

Engine switch Economy idle switch Oil warning light Voltage meter AC switch (120 V-20 A, NFB) AC receptacle (125 V-20 A, GFCI) AC switch (120 V-30 A, NFB) AC receptacle (125 V-30 A) AC receptacle (125/250 V-30 A) AC switch (120 V-50 A, NFB) AC switch (240 V-25 A, NFB) Exciter stator assembly Stator assembly Rotor assembly Oil level switch Spark plug TCI unit Resistor Oil warning unit Rectifier AVR Condenser Economy idle unit Ground terminal Solenoid valve i

34 5 6 56 789 0 q

2 1

wer

t

y

u

o

p

a

f

s

g

10 3-124

d

f

3-125

11

h

g

f

2

3

d

4

s

1

5

Rotor assembly Exciter field coil Sub coil Main coil Stator assembly Voltage meter NFB AC receptacle (125 V-20 A, GFCI) 9 AC receptacle (125 V-30 A)

1 2 3 4 5 6 7 8

B

YG6600D

B W

B W

120V

a

p

240V

Y

Y

Y

G

R

R

Br

R

0 AC receptacle (125/250 V30 A) q Ground terminal w Engine switch e Rectifier r Voltage adjuster t Condenser y AVR u Oil warning unit i Oil warning light

L/R L/W

G/R

L B/W

Y G G

Y GG

Br

R

L

G/Y

o

6

G Y L/W G Y L/W

V

B W W G B Y R G

o p a s d f g h

B W W G B Y R G

L G R

t

R

y

Br

L Y B/W B

u

7

G/Y

r

G/Y

8 7 Br

R

Br

G/R L/W B Y

8 7

B G/R G/R B L/W Y Y L/W

Y B/W

Br

w

B

9 7

G/Y R

Economy idle unit Economy idle solenoid valve Economy idle switch Fuel cut solenoid valve Charging coil Spark plug T.C.I.unit Oil level switch

B/W Y

B/W Y

i

7

L

G/Y

e

Color code B ..........Black Br .........Brown G ..........Green Gy ........Gray L...........Blue R ..........Red W .........White B/W ......Black/White G/R ......Green/White G/Y.......Green/Yellow L/W ......Blue/White R/W......Red/White Y ..........Yellow

G/R L/W B Y

L

0

B L/R

q

G/Y R

Current Model Specifications and Wiring Diagrams â&#x20AC;&#x201C; YG6600D

YG6600D WIRING DIAGRAM

ELECTRICAL COMPONENTS AND CIRCUIT DIAGRAM

ELEC

SPEC

GENERAL SPECIFICATIONS Yamaha Generator Theory & Diagnostics Guide

SPECIFICATIONS GENERAL SPECIFICATIONS Unit Model code number Dimensions: Overall length Overall width Overall height Dry weight Noise level: Engine: Engine type Cylinder arrangement Displacement Bore × Stroke Compression ratio Operating hours Fuel Fuel tank capacity Engine oil capacity Engine oil grade

EF6600DE 7CCB mm (in) mm (in) mm (in) kg (lb) dB(A)/Hzl

L (cm3) mm (in) 60 Hz · Hrs L (Imp gal, US gal) L (Imp qt, US qt)

894 (35.2) 520 (20.5) 527 (20.7) 91 (200.6) 74/60

YG6600D

670 (26.4) 510 (20.1) 577 (22.7) 86 (189.6)

YG6600DE

894 (35.2) 520 (20.5) 93 (205.0)

4-stroke OHV forced air cooled 1 0.357 (357) 85.0 × 63.0 (3.35 × 2.48) 8.1 : 1 6.8 Unleaded regular gasoline 23.0 (5.06, 6.08) 1.1 (0.97, 1.16) 4-stroke engine oil API service classification SE or SF, if not available, SD

(5W-30)

Lubrication system Air filter system Cooling system Ignition system Starting system Stopping system Rotating direction Governor type Electrical: Ignition system Spark plug type Gap

Forced splashing Semi-wet (Urethane foam) Forced air cooling TCI Electric and Recoil starter recoil starter Misfire Clockwise (from flywheel) Centrifugal weight system

mm (in)

BPR4ES (NGK) 0.7 ~ 0.8 (0.028 ~ 0.031)

20 3-126

Electric and recoil starter

Current Model Specifications and Wiring Diagrams – YG6600D

GENERAL SPECIFICATIONS SPEC Unit

EF6600DE

Generator: Type Number of phase Number of poles Excitation Initial excitation Driving method Rated power factor Frequency variation Voltage fluctuation AC output Rated voltage Frequency Rated output Rated current Safety device type Rated engine speed Economy idle engine speed Voltage regulation Insulation resistance Insulation class Stator Rotor Receptacle AC

YG6600D

YG6600DE

Brushless, self-exciting, single-phase, synchronous generator Single phase 2 Self magnetization Residual magnetization Direct connection 1 Less than 5% Less than 10% V Hz kVA A r/min r/min MΩ

120/240 60 6.0 50.0/25.0 NFB (No Fuse Breaker) 3,600 2,350 AVR More than 10 E class B class 20 A (125 V) (Duple) × 1, 30 A (125 V) × 1, 30 A (250/125 V) × 1

3-127

21

20 A (125 V) (Duple) × 2, 30 A (125 V) × 1, 30 A (250/125 V) ×1

Yamaha Generator Theory & Diagnostics Guide SPEC MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS ENGINE Unit Piston: Piston clearance <Limit> Piston skirt “D” <Limit> Measuring point “H” Oversize

EF6600DE

YG6600D

YG6600DE

mm (in)

1st 2nd Piston pin hole inside diameter <Limit> Piston pin: mm (in) Piston pin diameter <Limit> Piston ring: mm (in) Top ring Type Dimensions “B × T” End gap <Limit> Side clearance <Limit> 2nd ring Type Dimensions “B × T” End gap <Limit> Side clearance <Limit> Oil ring B Type Dimensions “B × T” T End gap <Limit>

0.015 ~ 0.029 (0.0006 ~ 0.0011) 0.100 (0.0039) 84.977 ~ 84.998 (3.3456 ~ 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 (0.035) 0.04 ~ 0.08 (0.0016 ~ 0.0031) 0.1 (0.0039) Taper 1.5 × 3.6 (0.059 × 0.142) 0.20 ~ 0.35 (0.008 ~ 0.014) 0.9 (0.035) 0.03 ~ 0.07 (0.0012 ~ 0.0028) 0.1 (0.0039) 3-piece type 3.0 × 3.0 (0.118 × 0.118) 0.20 ~ 0.70 (0.008 ~ 0.028) 0.9 (0.035)

3-128

22

Current Model Specifications and Wiring Diagrams – YG6600D MAINTENANCE SPECIFICATIONS SPEC

Unit Cylinder head: Warpage limit Cylinder: Inside diameter “D” <Limit> Taper limit Warpage limit Crankshaft: Big end side clearance “A” <Limit> Runout “B” <Limit> Crank pin outside diameter “C” <Limit> Connecting rod: Small end diameter “A” Oil clearance Big end diameter “B” Oil clearance <Limit> Camshaft: Camshaft outside diameter Cam dimension “A” IN <Limit> “A” EX <Limit> “B” IN <Limit> “B” EX <Limit> Camshaft journal diameter <Limit>

EF6600DE

YG6600D

YG6600DE

mm (in) 0.05 (0.0020) mm (in) 85.000 ~ 85.020 (3.3465 ~ 3.3472) 85.020 (3.3472) 0.05 (0.0020) 0.05 (0.0020) mm (in) 0.20 ~ 0.65 (0.008 ~ 0.026) 0.8 (0.031) 0.04 (0.0016) 35.969 ~ 35.984 (1.4161 ~ 1.4167) 35.9 (1.4134) mm (in) 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 (0.0039) mm (in)

32.55 ± 0.05 (1.281 ± 0.002) 32.40 (1.276) 32.55 ± 0.05 (1.281 ± 0.002) 32.40 (1.276) 26.08 ± 0.05 (1.027 ± 0.002) 25.93 (1.021) 26.08 ± 0.05 (1.027 ± 0.002) 25.93 (1.021) 15.965 ~ 15.990 (0.6285 ~ 0.6295) 15.950 (0.6280)

3-129 23

Yamaha Generator Theory & Diagnostics Guide SPEC MAINTENANCE SPECIFICATIONS

Unit Valve: Valve Face diameter “A” Stem diameter “B” <Limit> Stem length “C”

EF6600DE

YG6600D

YG6600DE

mm (in) IN EX IN EX IN EX IN EX

32.0 (1.26) 27.0 (1.06) 5.948 ~ 5.963 (0.2342 ~ 0.2348) 5.940 ~ 5.955 (0.2339 ~ 0.2344) 5.9 (0.2323) 5.9 (0.2323) 88.1 (3.47) 87.9 (3.46)

Valve face contact width “D”

IN EX <Limit> IN EX Valve seat contact width IN EX <Limit> IN EX Valve stem runout limit “θ” Valve guide Guide inside diameter IN EX Stem to guide clearance IN EX Valve clearance (cold) IN EX Push rod: Runout limit

0.7 ~ 0.9 (0.0276 ~ 0.0354) 0.7 ~ 0.9 (0.0276 ~ 0.0354) 1.4 (0.0551) 1.4 (0.0551) 0.7 ~ 0.9 (0.0276 ~ 0.0354) 0.7 ~ 0.9 (0.0276 ~ 0.0354) 1.4 (0.0551) 1.4 (0.0551) 0.01 (0.0004) 90° 6.000 ~ 6.012 (0.2362 ~ 0.2367) 6.000 ~ 6.012 (0.2362 ~ 0.2367) 0.037 ~ 0.064 (0.00146 ~ 0.00252) 0.045 ~ 0.072 (0.00177 ~ 0.00283) 0.08 ~ 0.12 (0.0031 ~ 0.0047) 0.08 ~ 0.12 (0.0031 ~ 0.0047) mm (in) 0.5 (0.02)

3-130 24

Current Model Specifications and Wiring Diagrams – YG6600D

MAINTENANCE SPECIFICATIONS SPEC Unit Valve spring: Free length

EF6600DE

YG6600D

YG6600DE

mm (in) IN EX IN EX IN EX IN EX

<Limit> Set length Set force Tilt limit Carburetor: Type/manufacture

36.2 (1.43) 36.2 (1.43) 34.0 (1.34) 34.0 (1.34) 29.0 (1.14) 29.0 (1.14) 10 kg (22.0 lb) 10 kg (22.0 lb) 1.6 (0.06) mm (in) BV26-20/ BV26-21/ MIKUNI MIKUNI 7CT70 7CT20 ø20 ø21 #116.3 #98.8 ø1.4 ø1.6 ø0.9 ø0.9 ø1.0 ø1.8 ø2.0 106 P 53 A #50 #63.8 #120 14.9 (0.59) 26 Ω at 23 °C (73.4 °F)

I.D. mark Bore size Main jet Main air jet Pilot air jet Pilot outlet Valve seat size Main nozzle Pilot jet Throttle valve Float height “H” Carburetor heater resistance

BV26-20/ MIKUNI 7CT70 ø20 #116.3 ø1.4 ø0.9 ø1.8 106 P #50

GENERATOR Unit

EF6600DE

Generator: Type Main coil AC voltage (with the sub coil coupler connected) 120 V (Br-R) 240 V (Br-L) Main coil AC voltage (with the sub coil coupler disconnected) 120 V (Br-R) 240 V (Br-L) Sub coil AC voltage (with the sub coil coupler disconnected) 120/240 V (G-G) Exciter stator coil voltage

YG6600D

YG6600DE

Brushless, self-exciting, single-phase, synchronous generator

V V

114 ~ 140 225 ~ 275

V V

20 ~ 30 40 ~ 60

V V

4 ~ 12 10 ~ 20

3-131

25

Yamaha Generator Theory & Diagnostics Guide SPEC MAINTENANCE SPECIFICATIONS

Unit Coil resistance Main coil (Br-R) (Br-L) Field coil (rotor assembly) Sub coil (G-G) Exciter stator coil Exciter rotor coil

EF6600DE (Ω ± 10%) (Ω ± 10%) (Ω ± 10%) (Ω ± 10%) (Ω ± 10%) (Ω ± 10%)

YG6600D

YG6600DE

YG6600D

YG6600DE

0.16 0.45 28 0.35 45 1.7

ELECTRICAL Unit

EF6600DE

Electrical: Ignition system Ignition timing at 3,600 r/min Spark plug type Gap Primary coil resistance (Ω ± 20%) Secondary coil resistance (KΩ ± 20%) Spark plug cap resistance (KΩ) Air gap between TCI unit and flywheel mm (in) Minimum spark gap mm (in) Charging coil resistance (battery charging) W-Ground (Ω ± 20%) G/R-Ground (Ω ± 20%) Economy idle system Economy idle voltage (DC) (economy idle unit) V Economy idle solenoid valve voltage (DC) V Economy idle solenoid valve resistance (Ω ± 10%) Electric starting system Depth of insulator mm (in)

Brush spring pressure Insulation resistance Wear limit length Holding coil resistance å-∫ Pull-in coil resistance å-ç Battery Capacity

N (Kgf, lbf) (MΩ) mm (in) (Ω ± 20%) (Ω ± 20%)

BTDC 23° ± 3° BPR4ES (NGK) 0.7 ~ 0.8 (0.028 ~ 0.031) 0.6 12 3.0 ~ 7.5 0.5 (0.020) 6 (0.24) 2.3 1.7

— 1.1

2.3 1.7

— —

10 ~ 18 10 ~ 18 35.5 0.4 ~ 0.8 (0.0157 ~ 0.0315) 13 (1.325, 2.91) More than 0.1 6 (0.24) 1.1 0.5

— — — —

0.4 ~ 0.8 (0.0157 ~ 0.0315) 13 (1.325, 2.91) More than 0.1 6 (0.24) 1.1 0.5

12 V-26 Ah

—

12 V-26 Ah

3-132 26

—

Current Model Specifications and Wiring Diagrams – YG6600D

WIRE ROUTING DIAGRAM SPEC

YG6600D å Condenser ∫ Negative side is indicated in black.

ç Economy idle unit

COLOR CODE B ......... Black Br ........ Brown L .......... Blue R ......... Red Y ......... Yellow B/W ..... Black/White G/Y ...... Green/Yellow L/R ...... Blue/Red

∂ Pass the longer brown lead through the economy idle unit coil.

A G/Y B

A

å

B/W L/R

Y Y

Br

∂

å

R

å

B/W Y

B/W

Br

R

B

Br

Br

Br

Br

L

Br

R R

Y Y

Br

G/Y Br

R G/Y

Br

Br

G/Y

R G/Y

L Br

Y G

30

3-133

L

Br

∫

B

W

Yamaha Generator Theory & Diagnostics Guide SPEC WIRE ROUTING DIAGRAM

YG6600DE å Condenser ∫ Negative side is indicated in black.

ç Economy idle unit

∂ Pass the longer brown lead through the economy idle unit coil.

COLOR CODE B ......... Black Br ........ Brown L .......... Blue R ......... Red Y ......... Yellow B/W ..... Black/White G/Y ...... Green/Yellow L/R ...... Blue/Red

A G/Y B

A

ç å L/R

R/W

Y

B/W Br

∂

R

B/W

Y

Y

R

B/W

Br

å

R

B

Br Br

L

Br

Br

Br

R

Br

R

Y Y

G/Y Br

R G/Y

Br

R

Br

G/Y

G/Y

Y G

31 3-134

L

B Br

L

Br

∫

W

Current ModelCIRCUIT Specifications and Wiring Diagrams ELEC – YG6600DE ELECTRICAL COMPONENTS AND DIAGRAM –

+

YG6600DE 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Q

Start switch Economy switch Engine switch Oil warning light Voltage meter AC switch (120 V-20 A, NFB) AC receptacle (125 V-20 A, GFCI) AC receptacle (125 V-20 A) AC receptacle (125 V-30 A) AC receptacle (125/250 V-30 A) AC switch (120 V, NFB) AC switch (240 V, NFB) Exciter stator assembly Stator assembly Rotor assembly Oil level switch Spark plug TCI unit Oil warning unit Rectifier AVR Condenser Economy idle unit Ground terminal Fuse (10 A) Rectifier/regulator Solenoid valve

PWV0350

PWV0360

G/Y

B

Y

G

PWV0370

3-135 23

3-136

24

X

B

W

V

B/W

4

1

3

G/Y

R/W

S

T

G/R

U

W

2

M

B W

Y G G Y Y G G G G

B W

Q

R

G/R

B W

B

R

B W

Y G G

Br

R

R

Br

L

L

L/W

P

L/R

120V

240V Y

Y

Y

Br

Br

R

K

Br

R

6

B/W

Y

Y

M

B W W G B Y R G

B/W

7

V

B W W G B Y R G

I

7

G/Y

L Y B/W B

L

Br

R

L

8

D Engine switch E Remote control terminal F Rectifier G Fuse (10 A) H Rectifier/regulator I AVR J Condenser K Economy idle unit L Oil warning unit M Oil warning light N Solenoid valve O Economy switch P Carburetor solenoid valve

G Y L/W

G Y L/W

1 Rotor assembly 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-30 A) B Ground terminal C Start switch

L/R L/W R

L B/W R/W W G/R G/R B

O

N

G

R

7

W G/R

Br

0

R

G

R

B

J

R

G/R L/W B Y

G/Y

B

E

B/W

Br R

Br

Y

B

B/W

A

G/Y

G/R L/W B Y

R

F

D

L G/Y

B

L/R

B

R

R

L/R........... Blue/Red L/W.......... Blue/White R/B .......... Red/Black R/W ......... Red/White

R/W

R/W

C

AND CIRCUIT DIAGRAM

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

COLOR CODE

B G/R G/R B L/W Y Y L/W

R/B

R/W

B R/B R B/W R/W Br

R

Q Carburetor heater R Battery S Starter motor T Magnetic switch U Charging coil V TCI unit W Spark plug X Oil level switch

R

W R G/R

H

Br

9

G/Y

YG6600DE WIRING DIAGRAM ELECTRICAL COMPONENTS

B

5

G

YG6600DE

Yamaha Generator Theory & Diagnostics Guide ELEC â&#x20AC;&#x201C; +

PWV0420

GENERAL SPECIFICATIONS

SPEC

Current Model Specifications and Wiring Diagrams – YG6600DE

EF6600DE

YG6600D

YG6600DE

7WW2 894 (35.2) 520 (20.5) 510 (20.1) 90 (198.4)

670 (26.4) 510 (20.1) 560 (22.0) 85 (187.4)

894 (35.2) 520 (20.5) 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 classification SE or SF, if not available, SD

(5W-30)

Forced splashing Semi-wet (Urethane foam) Forced air cooling TCI Recoil stater Misfire Clockwise (from flywheel) Centrifugal weight system

BPR4ES (NGK) 0.7 ~ 0.8 (0.028 ~ 0.031)

34

3-137

Yamaha Generator Theory & Diagnostics Guide GENERAL SPECIFICATIONS SPEC EF6600DE

YG6600D

Brushless, self-exciting, single-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 than 10 E class B class 20 A (125 V) × 1, 30 A (125 V) × 1, 20 A (250/125 V) × 1 30 A (250/125 V) × 1

3-138 36

YG6600DE

MAINTENANCE SPECIFICATIONS

SPEC

Current Model Specifications and Wiring Diagrams – YG6600DE

EF6600DE

YG6600D

0.015 ~ 0.029 (0.0006 ~ 0.0011) 0.100 (0.0039) 84.977 ~ 84.998 (3.3455 ~ 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 (0.0016 ~ 0.0031) 0.1 (0.0039) Taper 1.5 × 3.6 (0.059 × 0.142) 0.20 ~ 0.35 (0.008 ~ 0.014) 0.9 (0.0354) 0.03 ~ 0.07 (0.0012 ~ 0.0028) 0.1 (0.0039) 3-piece type 3.0 ~ 2.8 (0.118 ~ 0.110) 0.20 ~ 0.70 (0.008 ~ 0.028) 0.9 (0.0354)

38

3-139

YG6600DE

Yamaha Generator Theory & Diagnostics Guide SPEC MAINTENANCE SPECIFICATIONS

EF6600DE

YG6600D

0.05 (0.002) 85.000 ~ 85.020 (3.3465 ~ 3.3472) 85.020 (3.3472) 0.05 (0.002) 0.05 (0.002) 0.20 ~ 0.65 (0.008 ~ 0.026) 0.8 (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) 32.40 (1.276) 32.55 ± 0.05 (1.28 ± 0.002) 32.40 (1.276) 26.08 ± 0.05 (1.03 ± 0.002) 25.93 (1.021) 26.08 ± 0.05 (1.03 ± 0.002) 25.93 (1.021) 15.965 ~ 15.990 (0.6285 ~ 0.6295) 15.950 (0.6280)

3-140 40

YG6600DE

Current Model Specifications and Wiring Diagrams – YG6600DE

MAINTENANCE SPECIFICATIONS EF6600DE

YG6600D

32.0 (1.26) 27.0 (1.06) 5.948 ~ 5.963 (0.2342 ~ 0.2348) 5.940 ~ 5.955 (0.2339 ~ 0.2344) 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 ~ 0.2367) 6.000 ~ 6.012 (0.2362 ~ 0.2367) 0.037 ~ 0.064 (0.00146 ~ 0.00252) 0.045 ~ 0.072 (0.00177 ~ 0.00283) 0.08 ~ 0.12 (0.0031 ~ 0.0047) 0.08 ~ 0.12 (0.0031 ~ 0.0047) 0.5 (0.02)

3-141 42

SPEC

YG6600DE

©2009 Yamaha Motor Corporation, U.S.A. Printed in U.S.A.

LIT-BKTEC-GN-01