SERVICE MANUAL - My Generator

1 SERVICE MANUALEF7000EF7000 EEF7200EF7200 EEF7200DE7P6-F8197-E02014_05 1 ! 12014/05/29 15:46:41235618799 999000qetyiuopfdghjkl;zxcsaw4r1 Generator2 Rotor assembly 3 Exciter field coil4 Sub coil5 Main coil6 Stator assembly7 Control box8 Voltage/hour meter9 AC switch ( )0 AC receptacleq Engine switchw Rectifiere Remote control terminalr Fuset Rectifier/regulatory Voltage adjusteru Condenseri AVR (Automatic Voltage Regulator)o Oil warning unitp Economy control unita Oil warning lights Economy control switchd Enginef Economy control solenoidg Starter relayh Starter motorj Auto chokek Fuel cut solenoid valvel Battery; Charging coilz TCI unitx Spark plugc Oil level switchColor codeB BlackBr BrownG GreenL BlueLg Light greenO OrangeR RedW WhiteEF7200DE (CAN)2014 CIRCUIT DIAGRAMY YellowB/W Black/WhiteG/R Green/RedG/Y Green/YellowL/R Blue/RedL/W Blue/WhiteR/B Red/BlackR/G Red/GreenR/W 22014/05/29 15:46:42 FOREWORDThis SERVICE MANUAL has been prepared to introduce SERVICE procedure and data for the EF7000/EF7000E/EF7200/EF7200 complete information on SERVICE proce-dure of the engine, it is necessary to use fol-lowing SERVICE MANUAL :MZ SERIES ENGINE SERVICE MANUAL :7VB-F8197-E0 This MANUAL was written by the Yamaha Motor Powered Products Co.

2 , Ltd. 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 per-form maintenance and repairs on Yamaha generators have a basic understanding 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 Motor Powered Products Co., Ltd. is continually striving to further improve all mod-els manufactured 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 2014 by Yamaha Motor PoweredProducts Co., Edition, May 2014 All rights reserved.

3 Any reprinting orunauthorized use without the writtenpermission of Yamaha Motor Powered Products Co., expressly TO USE THIS MANUALPARTICULARLY IMPORTANT INFORMATIONP articularly important information is distin-guished in this MANUAL by the following is the safety alert symbol. It is used to alert you to potential personal injury haz-ards. Obey all safety messages that follow this symbol to avoid possible injury or WARNING indicates a hazardous situa-tion which, if not avoided, could result in death or serious NOTICE indicates special precautions that must be taken to avoid damage to the machine or other TIP provides key information to make proce-dures easier or TO USE THIS MANUALThis MANUAL is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential The MANUAL is divided into chapters and each chapter is divided into sections.

4 The current sec-tion title is shown at the top of each page Sub-section titles appear in smaller print than the section title To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section Numbers are given in the order of the jobs in the exploded diagram. A number indicates a dis-assembly step Symbols indicate parts to be lubricated or replaced 5. Refer to ILLUSTRATED SYMBOLS .9 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 6. This step explains removal procedure only. For installation, reverse the Jobs requiring more information (such as special tools and technical data) are described sequentially CAMS(AFT CRAN+CASE AND CRAN+S(AFT123345677891020 Nm ( m kgf, 14 ft lbf)OrderJob/Parts to removeQ tyRemarksReMoVING THe PISToN cAMSHAFT ANd crANKSHAFTR emove the parts in the order to CRANKCASE on Balancer shaft12 Camshaft13 Valve lifter24 Connecting rod cap15 Crankshaft16 Connecting rod17 Piston pin circlip28 Piston pin19 Piston110 Piston ring set1 PIST/N CAMS(AFT AND CRAN+S(AFT3-21 ENGPISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFTREMOVING THE BALANCER SHAFT, CAMSHAFT, AND VALVE LIFTER 1.))))

5 Remove: 9 Balancer shaft 1 TIPR emove the balancer shaft 1 when the bal-ancer shaft gear mark a and the crankshaft gear mark b are aligned. 2. Remove: 9 Camshaft 2 TIPR emove the camshaft 2 when the camshaft gear mark c and the crankshaft gear mark d are aligned. 3. Remove: 9 Intake valve lifter 9 Exhaust valve lifterCHECKING THE BALANCER SHAFT 1. Check: 9 Balancer gear teeth 9 Balancer shaft Wear/damage SYMBOLS(Refer to the illustration)SYMBOLDEFINITIONSYMBOLDEFIN ITIONG eneral informationPeriodic checks and adjustmentsEngineCarburetorElectricalTro ubleshootingSpecificationsFilling fluidLubricantSpecial toolT torqueWear limit, clearanceEngine speedElectrical dataReplace the part with a new base greaseMMolybdenum disulfide greaseEEngine oilMMolybdenum disulfide oilLTApply locking agent (LOCTITE )INDEXGENERAL INFORMATIONGENINFOPERIODIC CHECKSAND ADJUSTMENTSCHKADJENGINEENGCARBURETORELEC TRICALTROUBLESHOOTINGCARBELECTRBLSPECIFI CATIONSSPEC1234567 CHAPTER INFORMATIONMODEL VARIATIONS.

6 1-1 MACHINE IDENTIFICATION ..1-2 SERIAL NUMBER ..1-2 IMPORTANT INFORMATION ..1-3 PREPARATION FOR REMOVAL AND DISASSEMBLY CAUTION ON SERVICE ..1-3 NOTES ON REPLACEMENT PARTS ..1-4 GASKETS, OIL SEALS, AND O-RINGS ..1-4 BEARINGS AND OIL SEALS ..1-4 BASIC SERVICE INFORMATION ..1-5 ELECTRICAL SYSTEM ..1-5 SPECIAL TOOLS AND TESTERS ..1-8 CHAPTER CHECKS AND ADJUSTMENTSINTRODUCTION ..2-1 MAINTENANCE INTERVALS CHART ..2-1 PERIODIC MAINTENANCE/ LUBRICATION INTERVALS ..2-1 PERIODIC MAINTENANCE ..2-3 SPARK PLUG ..2-3 FUEL LEAKAGE ..2-5 ENGINE OIL LEAKAGE ..2-5 ENGINE OIL LEVEL ..2-5 REPLACING THE ENGINE OIL ..2-6 AIR FILTER ELEMENT ..2-7 MUFFLER ..2-8 FUEL TANK FILTER ..2-10 FUEL COCK STRAINER ..2-11 BREATHER HEAD DECARBONIZATION ..2-12 ADJUSTING THE VALVE CLEARANCE ..2-12 ADJUSTING THE ENGINE SPEED (Except for EF7000/EF7200) ..2-15 ADJUSTING THE ENGINE SPEED (For EF7000/EF7200).

7 2-16 RECOIL STARTER ..2-17 FITTINGS AND FASTENERS ..2-17 CHAPTER BOX ..3-1EF7200DE ..3-1 Except for EF7200DE ..3-3 INSTALLING THE CONTROL BOX ..3-5 AIR FILTER ..3-6 FUEL TANK, CANISTER ..3-7 CHECKING THE CANISTER (For EF7200DE CAN) ..3-9 MUFFLER ..3-10 INSTALLING THE MUFFLER ..3-11 ENGINE ..3-12 Generator ..3-13 REMOVING THE STATOR ASSEMBLY AND ROTOR ASSEMBLY ..3-15 INSTALLING THE STATOR ASSEMBLY AND ROTOR ASSEMBLY ..3-17 PISTON, CAMSHAFT, CRANKCASE, AND CRANKSHAFT ..3-18 CRANKCASE ..3-18 PISTON, CAMSHAFT AND CRANKSHAFT ..3-20 REMOVING THE BALANCER SHAFT, CAMSHAFT, AND VALVE LIFTER ..3-21 CHECKING THE BALANCER SHAFT ..3-21 INSTALLING THE VALVE LIFTER, BALANCER SHAFT, AND CAMSHAFT ..3-22 INSTALLING THE CRANKCASE COVER ..3-22 HANDLE AND WHEELS (FOR EF7200DE CAN) ..3-23 INSTALLING THE HANDLE ..3-25 INSTALLING THE WHEELS ..3-28 CHAPTER THE CARBURETOR.

8 4-1 DISASSEMBLING THE CARBURETOR ..4-3EF7000/EF7200 ..4-3EF7000E/EF7200E/EF7200DE ..4-5 CHECKING THE FUEL CUT SOLENOID VALVE ..4-7 CHAPTER COMPONENTS ..5-1EF7000 (CHN) ..5-2EF7000E (CHN) ..5-2EF7200 (SEA/AFR/RUS) ..5-2EF7200E (Except for OCE) ..5-2EF7200E (OCE) ..5-3EF7200DE (Except for CAN) ..5-3EF7200DE (CAN) ..5-3 CIRCUIT DIAGRAM ..5-4EF7000/EF7200 ..5-4EF7000E/EF7200E ..5-5EF7200DE (Except for CAN) ..5-6EF7200DE (CAN) ..5-7 CONTROL PANEL ..5-8EF7000/EF7200 ..5-8EF7000E/EF7200E (Except for OCE) ..5-10EF7200E (OCE) ..5-12EF7200DE (Except for CAN) ..5-14EF7200DE (CAN) ..5-16 BATTERY (EF7000E/EF7200E/EF7200DE) ..5-18 CHECKING AND CHARGING THE BATTERY ..5-19 FUSE (EF7000E/EF7200E/EF7200DE) ..5-26 CHECKING THE FUSE ..5-26 SWITCHES ..5-28 CHECKING THE SWITCH CONTINUITY ..5-28 IGNITION SYSTEM ..5-29 TROUBLESHOOTING CHART ..5-29 ELECTRIC STARTING SYSTEM (EF7000E/EF7200E/EF7200DE).

9 5-35 TROUBLESHOOTING CHART ..5-35 REMOVING THE STARTER MOTOR ..5-37 DISASSEMBLING THE STARTER MOTOR ..5-38 CHECKING THE BRUSH ..5-39 ASSEMBLING THE STARTER MOTOR ..5-39 CHARGING SYSTEM (EF7000E/EF7200E/EF7200DE) ..5-40 TROUBLESHOOTING CHART ..5-40 Generator SYSTEM ..5-43 TROUBLESHOOTING CHART ..5-43 ECONOMY CONTROL SYSTEM (EF7000E/EF7200E/EF7200DE) ..5-54 ECONOMY CONTROL SOLENOID ..5-54 INSTALLING THE ECONOMY CONTROL SOLENOID ..5-55 ECONOMY CONTROL SYSTEM DIAGRAM ..5-56 TROUBLESHOOTING CHART ..5-57 CHAPTER ..6-1 CHAPTER SPECIFICATIONS ..7-1 MAINTENANCE SPECIFICATIONS ..7-4 ENGINE ..7-4 ELECTRICAL ..7-7 Generator ..7-8 TIGHTENING TORQUES ..7-10 GENERAL TORQUE SPECIFICATIONS ..7-12 LUBRICATION POINTS AND TYPE OF LUBRICANTS ..7-13 WIRE ROUTING DIAGRAM ..7-14 CONTROL PANEL AND CONTROL BOX (EF7000/EF7200) ..7-14 CONTROL PANEL AND CONTROL BOX (EF7000E/EF7200E).

10 7-16 CONTROL PANEL AND CONTROL BOX (Except for EF7200DE CAN)..7-18 CONTROL PANEL AND CONTROL BOX (For EF7200DE CAN) ..7-20 BACK SIDE AND LEFT SIDE VIEW (For EF7200DE CAN) ..7-22 UPPER SIDE VIEW (EF7000E/EF7200E/EF7200DE) ..7-23 UPPER SIDE VIEW (EF7000/EF7200) ..7-24 ENGINE ..7-25 Generator (EF7000/EF7000E/ EF7200/EF7200E) ..7-26 Generator (Except for EF7200DE CAN) ..7-27 Generator (For EF7200DE CAN) ..7-281-1 GENINFOMODEL VARIATIONSGENERAL INFORMATIONMODEL VARIATIONSM odel code number7P627P63 Model nameEF7200DE EF7200DE EF7200DE EF7200EF7200E EF7200E EF7000EF7000 EEF7200EF7200 EStarting serial number*7P6-4000101 7P6-4030101 7P6-4040101 7P6-0300101 7P6-0360101 7P6-5000101 7P6-5010101 7P6-5110101 7P6-5130101 7P6-5140101 Voltage/Frequency120/240 V-60 Hz 120/240 V-60 Hz 120/240 V-60 Hz220 V-50 Hz 220 V-50 Hz 230 V-50 Hz 220 V-50 Hz 220 V-50 Hz 220 V-50 Hz 220 V-50 HzDestinationCSA/SEACANSAUSEA/AFROCECHNR USAC receptacle15 A 125 V 2 30 A 125 V 1 30 A 250 V/125 V 115 A 125 V 2 30 A 125 V 1 30 A 250 V/125 V 115 A 125 V 2 30 A 125 V 1 30 A 250 V/125 V 120 A 250 V 2 20 A 250 V 2 15 A 250 V 2 20 A 250 V 2 20 A 250 V 2 20 A 250 V 2 20 A 250 V 2 Starter motor333 33 3 3 Dual voltage333 Voltage/hour