Yamaha EF3300 EF4000 EF4000D Service Manual
DESCRIPTION:
Yamaha EF3300 EF4000 EF4000D Service Manual
FOREWORD:
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 edumtion 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 pro-V cedures inherent to generator repair technology. Vifithout 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.
MANUAL FORMAT:
The procedures in this manual are organized in a sequential, step-by-step format. The infor- mation has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explana— tions of all cflsassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course.
- Bearings
- Pitting/damage —> Replace.
TABLE OF CONTENTS:
Yamaha EF3300 EF4000 EF4000D Service Manual
CHAPTER 1
GENERAL INFORMATION
MACHINE IDENTIFICATION 1-1
SERIAL NUMBER 1-1
STARTING SERIAL NUMBER 1-1
ELECTRICAL COMPONENTS 1-2
EF3300 1-2
EF4000 (220 V-50 Hz) 1-3
EF4000 (220 V-50 Hz) 1-4
EF4000 (240 V-50 Hz) 1-5
EF4000D 1-6
IMPORTANT INFORMATION 1-7
PREPARATION FOR REMOVAL AND
DISASSEMBLY 1-7
CAUTION ON SERVICE 1-7
NOTES ON SERVICE 1-7
ALL REPLACEMENT PARTS 1-8
GASKETS, OIL SEALS,
AND O-RINGS 1-8
BEARINGS AND OIL SEALS 1-8
SPECIAL TOOLS AND TESTERS 1-9
CHAPTER 2
PERIODIC INSPECTIONS AND
ADJUSTMENTS
INTRODUCTION 2-1
PERIODIC MAINTENANCE/LUBRICATION
INTERVALS 2-1
ENGINE 2-2
ENGINE OIL LEAKAGE
CHECKING 2-2
OIL LEVEL CHECKING 2-2
OIL REPLACEMENT 2-3
FUEL LEAKAGE 2-4
FUEL COCK STRAINER
INSPECTION 2-4
FUEL TANK FILTER 2-5
AIR FILTER ELEMENT 2-6
MUFFLER 2-7
VALVE CLEARANCE
ADJUSTMENT 2-8
COMPRESSION PRESSURE 2-10
GOVERNOR ADJUSTMENT 2-11
RATED ENGINE SPEED
INSPECTION 2-11
RATED ENGINE SPEED
ADJUSTMENT 2-12
AIR GAP BETWEEN TCI UNIT
AND FLYWHEEL 2-13
BREATHER HOSE 2-14
ELECTRICAL 2-15
SPARK PLUG 2-15
ENGINE SWITCH 2-16
PILOT LIGHT
(EF3300/EF4000, 220 V-50 Hz) 2-16
VOLTAGE METER (EF3300) 2-17
VOLTAGE METER
(EF4000, 220 V-50 Hz
/EF4000, 240 V-50 Hz) 2-17
VOLTAGE METER (EF4000D) 2-17
AC SWITCH (NFB)
(EF3300/EF4000) 2-18
AC SWITCH (NFB) (120 V)
(EF4000D) 2-18
AC SWITCH (NFB) (240 V)
(EF4000D) 2-19
RECEPTACLE (EF3300/EF4000) 2-19
RECEPTACLE (EF4000D) 2-20
CHAPTER 3
ENGINE
CONTROL PANEL 3-1
AIR CLEANER AND FUEL TANK 3-7
BREATHER HOSE
INSTALLATION 3-8
MUFFLER 3-9
MUFFLER ASSEMBLY 3-10
CONTROL BOX 3-11
ENGINE 3-12
CYLINDER HEAD COVER
AND CYLINDER HEAD 3-13
PUSH ROD INSPECTION 3-14
CYLINDER HEAD INSPECTION 3-14
CYLINDER HEAD ASSEMBLY 3-15
BREATHER HOSE ASSEMBLY 3-15
VALVE 3-16
VALVE AND VALVE SPRING
REMOVAL 3-17
VALVE AND VALVE SPRING
INSPECTION 3-17
ROCKER ARM INSPECTION 3-18
VALVE SEAT INSPECTION 3-19
VALVE LAPPING 3-20
VALVE AND VALVE SPRING
ASSEMBLY 3-21
RECOIL STARTER 3-22
RECOIL STARTER
DISASSEMBLY 3-23
RECOIL STARTER INSPECTION 3-23
RECOIL STARTER ASSEMBLY 3-24
FLYWHEEL 3-26
FLYWHEEL REMOVAL 3-27
FLYWHEEL INSTALLATION 3-27
GENERATOR 3-28
STATOR ASSEMBLY AND
ROTOR ASSEMBLY REMOVAL 3-29
STATOR ASSEMBLY AND ROTOR
ASSEMBLY INSTALLATION 3-30
GOVERNOR 3-31
CRANKCASE COVER AND
CRANKCASE 3-32
CRANKCASE (CYLINDER)
INSPECTION 3-33
CRANKCASE COVER
INSPECTION 3-33
FLYWEIGHT SHAFT GEAR
INSPECTION 3-34
CRANKCASE COVER
INSTALLATION 3-34
PISTON, CONNECTING ROD,
CAMSHAFT AND CRANKSHAFT 3-35
CAMSHAFT INSPECTION 3-36
VALVE LIFTER INSPECTION 3-37
PISTON AND PISTON PIN
INSPECTION 3-37
PISTON RING INSPECTION 3-38
CRANKSHAFT INSPECTION 3-39
CONNECTING ROD OIL
CLEARANCE INSPECTION 3-40
PISTON RING AND PISTON
ASSEMBLY 3-41
CONNECTING ROD AND
CRANKSHAFT ASSEMBLY 3-42
CAMSHAFT ASSEMBLY 3-43
CARBURETOR 3-44
FLOAT HEIGHT INSPECTION 3-46
TROUBLESHOOTING 3-47
CHAPTER 4
ELECTRICAL
ELECTRICAL COMPONENTS 4-1
EF3300 4-1
EF4000 (220 V-50 Hz) 4-2
EF4000 (220 V-50 Hz) 4-3
EF4000 (240 V-50 Hz) 4-4
EF4000D 4-5
CIRCUIT DIAGRAM 4-6
EF3300 4-6
EF4000 (220 V-50 Hz) 4-7
EF4000 (220 V-50 Hz) 4-8
EF4000 (240 V-50 Hz) 4-9
EF4000D4-10
SWITCHES 4-11
CHECKING SWITCH
CONTINUITY 4-11
IGNITION SYSTEM 4-12
TROUBLESHOOTING CHART 4-12
OIL WARNING SYSTEM 4-16
TROUBLESHOOTING CHART 4-16
GENERATOR SYSTEM 4-18
TROUBLESHOOTING CHART 4-18
CHAPTER 5
SPECIFICATIONS
GENERAL SPECIFICATIONS 5-1
MAINTENANCE SPECIFICATIONS 5-5
ENGINE 5-5
ELECTRICAL 5-13
TIGHTENING TORQUE 5-17
GENERAL TORQUE
SPECIFICATIONS 5-18
DEFINITION OF UNITS 5-18
WIRE ROUTING DIAGRAM 5-19
CONTROL BOX PANEL AND BEHIND
CONTROL BOX 5-19
EF3300 5-19
EF4000 (220 V-50 Hz) 5-20
EF4000 (220 V-50 Hz) 5-21
EF4000 (240 V-50 Hz) 5-22
EF4000D 5-23
ENGINE AND GENERATOR 5-24
EF3300 5-24
EF4000 5-25
EF4000D 5-26
EF3300/EF4000/EF4000D 5-27
VIDEO PREVIEW OF THE MANUAL:
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