Yamaha Generator Inverter EF3000iseb&c SpplemService manual

SUPPLEMENTARY SERVICE MANUAL EF3000iSE EF3000iSEB LIT-19616-01-20 7CH-28197-10 310144

FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the EF3000iSE and EF3000iSEB. For complete information on service procedures, it is necessary to use this Supplementary Ser- vice Manual 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. EF3000iSE/EF3000iSEB SERVICE MANUAL: 7WL-28197-10 (310133) E. October 2002 LIT-19616-01-03 EF3000iSE/EF3000iSEB SUPPLEMENTARY SERVICE MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st Edition, July 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-19616-01-20 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 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................................. 12 DEFINITION OF UNITS ........................ 12 WIRE ROUTING DIAGRAM .................. 13 CONTROL PANEL........................... 13 BEHIND CONTROL PANEL AND CONTROL BOX INTERIOR .... 13 BEHIND CONTROL BOX ................ 13 ENGINE AND GENERATOR (EF3000iSE) .................................... 14 ENGINE AND GENERATOR (EF3000iSEB) .................................. 17

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. 1 PCH0060 SWL1020J STARTING SERIAL NUMBER EF3000iSE: 7CH-230101 ~ EF3000iSEB: 7CH-200101 ~ NOTE: Designs and specifications are subject to change without notice.

2 GEN INFO MACHINE IDENTIFICATION

3 SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Unit EF3000iSE/EF3000iSEB Model code number 7CH2 Dimensions: Overall length mm (in) 680 (26.8) Overall width mm (in) 445 (17.5) Overall height mm (in) 555 (21.9) Dry weight kg (lb) 67 (147.7) (EF3000iSE) 69 (152.1) (EF3000iSEB) Engine: Engine type 4-stroke, OHV, forced air cooled Cylinder arrangement 1 Displacement L (cm 3 ) 0.171 (171) Bore × Stroke mm (in) 66.0 × 50.0 (2.60 × 1.97) Compression ratio 8.5:1 Standard compression pressure kPa (kg/cm 2 , psi) 400 ~ 600 (4 ~ 6, 57 ~ 85) Rated output 60 Hz · kW (PS)/3,800 r/min 3.5 (4.7) Operating hours 60 Hz · Hrs 1/4 load (economy switch is on) 20.5 Rated load (economy switch is on) 8.0 Fuel Unleaded regular gasoline Fuel tank capacity L (Imp gal, US gal) 13.0 (2.86, 3.43) Engine oil quantity L (Imp qt, US qt) 0.6 (0.53, 0.63) Engine oil grade 4-stroke engine oil API service classification SE or SF, if not available, SD Electrical: Ignition system TCI Spark plug type BPR4ES (NGK) Gap mm (in) 0.7 ~ 0.8 (0.028 ~ 0.031) GENERAL SPECIFICATIONS

4 SPEC Generator: Type Multi pole rotating field magnet Initial excitation Permanent magnet Driving method Direct connection Rated power factor 1.0 Frequency variation Instantaneous Less than 1% Settling Less than 0.1% Settling time Less than 1 sec Voltage fluctuation Instantaneous Less than 20% Settling Less than 3% Settling time Less than 2 sec AC output Rated voltage V 120 Frequency Hz 60 Rated output kVA 2.8 Rated current A 23.3 DC output Rated voltage V 12 Rated current A 12 Safety device type AC Electronic no fuse breaker DC Circuit breaker (No fuse breaker) Engine speed (no load) r/min 3,800 Rated engine speed r/min 3,800 Economy engine speed (no load) r/min 2,800 ± 50 Voltage regulation Voltage feed back system Voltage stability Within ± 4% Frequency stability Hz Within ± 1.0 Rotating speed control Throttle motor control type Wave distortion ratio Less than 2.5% Number of phase AC output (main coil) Three phase DC output (sub coil) Single phase Insulation resistance MΩ Over 10 Insulation type B type Receptacle AC 20 A (Duple) × 1, 30 A × 1 DC 12 A × 1 Unit EF3000iSE/EF3000iSEB GENERAL SPECIFICATIONS

5 SPEC MAINTENANCE SPECIFICATIONS ENGINE Unit EF3000iSE/EF3000iSEB Piston: mm (in) Piston clearance 0.015 ~ 0.040 (0.00059 ~ 0.00157) <Limit> 0.15 (0.00591) Piston skirt “D” 65.975 ~ 65.990 (2.5974 ~ 2.5980) <Limit> 65.9 (2.5945) Measuring point “H” 10.0 (0.4) Oversize 1st 66.225 ~ 66.240 (2.6073 ~ 2.6079) 2nd 66.475 ~ 66.490 (2.6171 ~ 2.6177) Piston pin hole inside diameter 16.002 ~ 16.013 (0.6300 ~ 0.6304) <Limit> 16.043 (0.6316) Piston pin: mm (in) Piston pin diameter 15.995 ~ 16.000 (0.6297 ~ 0.6299) <Limit> 15.975 (0.6289) Piston ring: mm (in) Top ring Type Barrel face Dimensions “B × T” 1.5 × 2.7 (0.0591 × 0.1063) End gap 0.20 ~ 0.40 (0.0079 ~ 0.0157) <Limit> 0.65 (0.0256) Side clearance 0.04 ~ 0.08 (0.0016 ~ 0.0031) <Limit> 0.13 (0.0051) 2nd ring Type Taper Dimensions “B × T” 1.5 × 2.7 (0.0591 × 0.1063) End gap 0.20 ~ 0.40 (0.0079 ~ 0.0157) <Limit> 0.75 (0.0295) Side clearance 0.02 ~ 0.06 (0.0008 ~ 0.0024) <Limit> 0.12 (0.0047) Oil ring Type Solid Dimensions “B × T” 2.5 × 2.8 (0.0984 × 0.1102) End gap 0.20 ~ 0.70 (0.0079 ~ 0.0276) <Limit> 0.9 (0.0354) Cylinder head: mm (in) Warpage limit 0.05 (0.0020) Cylinder: mm (in) Inside diameter “D” 66.005 ~ 66.015 (2.5986 ~ 2.5990) <Limit> 66.020 (2.5992) Taper limit 0.05 (0.0020) T B B T B T MAINTENANCE SPECIFICATIONS

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Yamaha Generator Inverter EF3000iseb&c SpplemService manual

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