service repair workshop manual

1. SERVICE MANUAL

2. 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
education into one manual, so it is assumed
that persons using this book to perform main-
tenance and repairs on Yamaha generators
have a basic understanding of the mechani-
cal precepts and procedures inherent to gen-
erator repair technology. Without such knowl-
edge, attempted repairs or service to this
model may render it unfit for use and/or un-
safe.
Yamaha Motor Company Ltd. is continually
striving to further improve all models manufac-
tured by Yamaha. Modifications and signifi-
cant 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 IN-
VOLVED!
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 ma-
chine.
A NOTE provides key information to make pro-
cedures easier or clearer.
MANUAL FORMAT
The procedures in this manual are organized
in a sequential, step-by-step format. The in-
formation 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.,
SBearings
Pitting/damage ! Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams be-
fore each disassembly section for ease in
identifying the correct disassembly and as-
sembly procedures.
WARNING
CAUTION:
NOTE:
EDL13000TE
SERVICE MANUAL
© 1999 by Yamaha Motor Co., Ltd.
1st Edition, July 1999
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in JAPAN

3. CONTENTS
CHAPTER 1.
GENERAL INFORMATION
ENGINE IDENTIFICATION 1-1. . . . . . . . . . .
IMPORTANT INFORMATION 1-2. . . . . . . . .
SPECIAL TOOLS 1-4. . . . . . . . . . . . . . . . . . .
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS 2-1. . . . . . . .
DIMENSIONS 2-3. . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SPECIFICATIONS 2-4. . .
ELECTRICAL SPECIFICATIONS 2-10. . . .
GENERATOR SPECIFICATIONS 2-11. . . .
CHAPTER 3.
PERIODIC INSPECTIONS
AND ADJUSTMENTS
ENGINE BODY 3-1. . . . . . . . . . . . . . . . . . . . .
LUBRICATION SYSTEM 3-4. . . . . . . . . . . . .
COOLING SYSTEM 3-7. . . . . . . . . . . . . . . . .
FUEL SYSTEM 3-9. . . . . . . . . . . . . . . . . . . . .
STARTING SYSTEM 3-15. . . . . . . . . . . . . . .
GLOW SYSTEM 3-18. . . . . . . . . . . . . . . . . . .
KEY SWITCH 3-20. . . . . . . . . . . . . . . . . . . . .
STOP SYSTEM 3-21. . . . . . . . . . . . . . . . . . . .
CHARGING SYSTEM 3-23. . . . . . . . . . . . . .
TIGHTNING TORQUES 3-26. . . . . . . . . . . . .
PERIODIC MAINTENANCE/
LUBRICATION INTERVALS 3-27. . . . .
DAILY CHECK POINTS 3-28. . . . . . . . . . . . .
CHECK POINTS OF EVERY
50 HOURS 3-29. . . . . . . . . . . . . . . . . . . . .
CHECK POINTS OF EVERY
100 HOURS 3-30. . . . . . . . . . . . . . . . . . . .
CHANGING OF EVERY 200 HOURS 3-32. .
CHECK POINTS OF EVERY
500 HOURS 3-33. . . . . . . . . . . . . . . . . . . .
CHECK POINTS OF EVERY
800 HOURS 3-35. . . . . . . . . . . . . . . . . . . .
CHECK POINTS OF 1000 HOURS 3-35. . .
CHAPTER 4.
ENGINE
MEASURING AND ADJUSTING 4-1. . . . . .
ENGINE 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD COVER 4-4. . . . . . . . . . .
ROCKER ARM AND PUSH ROD 4-5. . . . .
INTAKE/EXHAUST MANIFOLD 4-7. . . . . .
CYLINDER HEAD AND TAPPETS 4-8. . . .
VALVE AND VALVE SPRING 4-9. . . . . . . . .
EXTERNAL COMPONENTS/
CYLINDER HEAD COVER 4-10. . . . . . .
INJECTION PIPE/NOZZLE/
ROCKER ARM AND PUSH ROD 4-11. .
TAPPETS/CYLINDER HEAD AND
VALVES 4-13. . . . . . . . . . . . . . . . . . . . . . .
SPEED CONTROL PLATE 4-15. . . . . . . . . .
GEAR CASE 4-16. . . . . . . . . . . . . . . . . . . . . .
INJECTION PUMP AND
CAMSHAFT 4-17. . . . . . . . . . . . . . . . . . . .
TIMING GEAR AND CAMSHAFT 4-19. . . .
PISTON AND CONNECTING ROD 4-23. . .
FLYWHEEL AND CRANKSHAFT 4-27. . . .
CHECK THE CYLINDER HEAD AND
VALVES 4-32. . . . . . . . . . . . . . . . . . . . . . .
CHECK THE PISTON AND
CONNECTING ROD 4-37. . . . . . . . . . . .
CHECK THE TIMING GEAR AND
CAMSHAFT 4-39. . . . . . . . . . . . . . . . . . . .
CHECK THE CRANKSHAFT 4-42. . . . . . . .
CHECK THE CYLINDER 4-46. . . . . . . . . . . .
OIL PUMP 4-47. . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 5.
COOLING SYSTEM
WATER PUMP/THERMOSTAT 5-1. . . . . . .
CHAPTER 6.
FUEL SYSTEM
INJECTION NOZZLE AND INJECTION
PUMP 6-1. . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 7.
ELECTRICAL
DYNAMO AND REGULATOR 7-1. . . . . . . .
STARTER AND GLOW PLUG 7-2. . . . . . . .
STARTER MOTOR 7-3. . . . . . . . . . . . . . . . . .
GENERATOR 7-9. . . . . . . . . . . . . . . . . . . . . .
POWER SOURCE 7-9. . . . . . . . . . . . . . . . . .
GENERATOR 7-10. . . . . . . . . . . . . . . . . . . . .
CONTROL FUNCTION 7-11. . . . . . . . . . . . .
CONTROL BOX 7-12. . . . . . . . . . . . . . . . . . .
PANEL WIRING DIAGRAM 7-15. . . . . . . . .
WIRING DIAGRAM (380/220 V) 7-16. . . . .
WIRING DIAGRAM (220/127 V) 7-17. . . . .
WIRING DIAGRAM (D.C. 12 V) 7-18. . . . . .
CHAPTER 8.
TROUBLESHOOTING
ENGINE SYSTEM 8-1. . . . . . . . . . . . . . . . . . .

4. 1-1
1
GENERAL INFORMATION
ENGINE IDENTIFICATION
SERIAL NUMBER
When contacting the manufacturer, always
specify your engine model name and serial
number.
CYLINDER NUMBER
D722 diesel engine are designated as shown
in the figure.
The sequence of cylinder numbers is given
as No.1, No.2, No.3 starting from the gear
case side.
PRECAUTION AT OVERHEATING
Take the following actions in the event the
coolant temperature be nearly or more than
the boiling point, what is called “Overheat-
ing”.
(1) Stop the machine operation in a safe
place and keep the engine unloaded id-
ling.
(2) Don’t stop the engine suddenly, but stop
it after about 5 minutes of unloaded id-
ling.
(3) Keep yourself well away from the ma-
chine for further 10 minutes or while the
steam spout out.
(4) Checking that there gets no danger such
as burn, get rid of the causes of over-
heating according to the manual.
And then, start again the engine.

5. 1-2
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY
CAUTION ON SERVICE
1. Fire prevention
When servicing the engine, always keep the engine and your-
self away from fire.
NOTES ON SERVICE
1. Correct tools
Be sure to use the correct special tool for the job to guard
against damage.
2. Oil, grease and seals
Be sure to use genuine Yamaha oils, grease and sealers, or the
equivalents.
3. Expendable parts
Always replace the gaskets, O-rings, cotterpins and circlips with
new parts when servicing engine.
4. Tightening torque
Be sure to follow torque specifications. When tightening bolts,
nuts or screws, start with the largest-diameter fastener and
work from an inner position to an outer position in a crisscross
pattern.
5. Notes on disassembly and assembly
a. Parts should be cleaned in solvent and blown dry with com-
pressed air after disassembly.
b. Contact surfaces of moving parts should be oiled when reas-
sembled.
c. Make sure that the parts, move smoothly after each section of
the machine is assembled.

6. 1-3
CAUTION:
ALL REPLACEMENT PARTS
1. We recommend the use of genuine Yamaha parts for all re-
placements. Use oil and/or grease, recommended by Yamaha,
for assembly and adjustment.
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, seals, and O-rings should be replaced when an en-
gine is overhauled. All gaskets surfaces, oil seal lips, and O-
rings must be cleaned.
2. Properly oil all mating parts and bearings during reassembly.
Apply grease to the oil seal lips.
BEARING AND OIL SEALS
1. Install the bearing(s) 1 and oil seal(s) 2 with their manufac-
ture’s marks or numbers facing outward. (In other words, the
stamped letters must be on the side exposed to view.) When
installing oil seal(s), apply a light coating of light-weight lithium
base grease to the seal lip(s). Oil the bearings liberally when
installing.
Do not use compressed air to spin the bearings dry. This
causes damage to the bearing surfaces.

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8. 1-4
SPECIAL TOOLS
Flywheel puller (For vertical type diesel
engines)
Application: Use exclusively to take off the
flywheel of all vertical type die-
sel engines safely and easily.
Valve seat cutter set
Application: Use for correcting valve seats.
Special-use puller set
Application: Use for pulling out bearings,
gears and other parts.
Crank sleeve setter
Application: Use to fix the crankshaft
sleeve of the engine models.

9. 1-5
Diesel engine compression tester
Application: Use for measuring diesel en-
gine compression pressure.
Oil pressure tester
Application: Use for measuring lubricating
oil pressure.
Connecting rod alignment tool
Application: Use for checking the connect-
ing rod alignment.
Applicable: Connecting rod big end dia-
range meter 30 to 75 mm (1.18 to
2.95 in. dia.) Connecting rod
length 65 to 330 mm (2.56 to
12.99 in.)
Plastigage
Application: Use for checking the oil clear-
ance between crankshaft and
bearing, etc.
Measuring: Green 0.025 to 0.076 mm
range (0.001 to 0.003 in.)
Red 0.051 to 0.152 mm
(0.002 to 0.006 in.)
Blue 0.102 to 0.229 mm
(0.004 to 0.009 in.)

10. 1-6
Unit: mm (in.)
Unit: mm (in.)
(0.45)
Unit: mm (in.)
NOTE:
Red check (Crack check liquid)
Application: Use for checking cracks on cyl-
inder head, cylinder block, etc.
(use the goods on the market)
SThe following special tools are not pro-
vided, so make them referring to the fig-
ures.
Valve guide replacing tool
Application: Use to press out and press fit
the valve guide.
Crankshaft bearing 1 replacing tool
Application: Use to press out and press fit
the crankshaft bearing 1.
Connecting rod small end bushing tool
Application: Use to press out and press fit
the connecting rod small end
bushing.

11. 1-7
Unit: mm (in.)
Unit: mm (in.) idle gear bushing replacing tool
Application: Use to press out and press fit
the idle gear bushing.
Injection pump pressure tester
Application: Use to check the fuel tight-
ness.
A Pressure gauge, full scale: more than
24.9 MPa (300 kgf/cm2, 4267 psi)
B Copper gasket
C Flange (material: steel)
D Hex. nut, 27 mm (1.06 in.) across the flat
(material: steel)
E Injection pipe
a Adhesive application
b Fillet welding on the enter circumference