ALL Yamaha EF2800i Inverter Generator Service Repair Manual

SUPPLEMENTARY SERVICE MANUAL EF2800i YG2800i LIT-19616-01-13 7VU-28197-12 331142

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the EF2800i/YG2800i. For complete information on service procedures, it is neces- sary to use this Supplementary Service Man- ual together with following manual: NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha generators have a basic under- standing of the mechanical precepts and procedures inherent to generator repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit for use and/or unsafe. Yamaha Motor Company Ltd. is continually striving to further improve all models manufac- tured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer. MANUAL FORMAT The procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explana- tions of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/damage → Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying the correct disassembly and assembly procedures. EF2800i SERVICE MANUAL: 7VU-28197-10 (310115) E. November 2000 LIT-19616-00-92 YG2800i SUPPLEMENTARY SERVICE MANUAL: 7VU-28197-11 (310128) E. November 2001 LIT-19616-00-97 EF2800i/YG2800i SUPPLEMENTARY SERVICE MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st Edition, September 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-19616-01-13 WARNING CAUTION:

ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 through 5 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Periodic inspections and adjustments 3 Engine 4 Electrical 5 Specifications Illustrated symbols 6 through B are used to identify the specific tools and test equipment. 6 Filling fluid 7 Lubricant 8 Special tool 9 Tightening 0 Wear limit, clearance A Engine speed B Ω, V, A Illustrated symbols C through K in the exploded diagram indicate the grades of lubricant and the locations of the lubrication points. C Apply engine oil D Apply gear oil E Apply molybdenum disulfide oil F Apply wheel bearing grease G Apply lightweight lithium-soap base grease H Apply molybdenum disulfide grease I Apply a locking agent (LOCTITE ® ) J Apply Yamaha bond K Use a new one 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K GEN INFO INSP ADJ ENG – + ELEC SPEC T R . . E G M B LS M LT 4 New

CONTENTS GENERAL INFORMATION .............................................................................................................. 1 MACHINE IDENTIFICATION ...................................................................................................... 1 SERIAL NUMBER.................................................................................................................. 1 STARTING SERIAL NUMBER .............................................................................................. 1 ELECTRICAL ................................................................................................................................... 2 CIRCUIT DIAGRAM .................................................................................................................... 2 SPECIFICATIONS ............................................................................................................................ 3 GENERAL SPECIFICATIONS .................................................................................................... 3 MAINTENANCE SPECIFICATIONS ........................................................................................... 5 ENGINE ................................................................................................................................. 5 GENERATOR AND ELECTRICAL ........................................................................................ 8 LUBRICATION POINTS AND LUBRICANT TYPES ................................................................... 9 TIGHTENING TORQUE ............................................................................................................ 10 GENERAL TORQUE SPECIFICATIONS .................................................................................. 11 DEFINITION OF UNITS ............................................................................................................ 11 WIRE ROUTING DIAGRAM ...................................................................................................... 12 CONTROL BOX PANEL AND BEHIND CONTROL BOX (EF2800i) ................................... 12 CONTROL BOX PANEL AND BEHIND CONTROL BOX (YG2800i) .................................. 13 ENGINE AND GENERATOR ............................................................................................... 14

1 GEN INFO MACHINE IDENTIFICATION GENERAL INFORMATION MACHINE IDENTIFICATION SERIAL NUMBER The serial number is printed on a label 1 which is affixed to the generator as shown. NOTE: The first three characters of this number are for model identification, the remaining digits are the unit production number. PVU0010 PVU0020 STARTING SERIAL NUMBER 7VU-200101~ (EF2800i) 7VU-240101~ (YG2800i) NOTE: Designs and specifications are subject to change without notice.

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ALL Yamaha EF2800i Inverter Generator Service Repair Manual

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