YAMAHA EDL20000TE, EDL26000TE SERVICE MANUAL

SUPPLEMENTARY SERVICE MANUAL

FOREWORD

This Supplementary Service Manual has been
prepared to introduce electrical new service
and electrical new data for the EDL20000TE,
EDL26000TE. For complete information, on
service procedures, it is necessary to use this
Supplementary Service Manual together with
diesel engine workshop manual:

DIESEL ENGINE WORKSHOP MANUAL:
(97897-01644) E.F.D. June 2002

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 understand­ing of the mechanical concepts and procedures
inherent in generators repair. Without such
knowledge, attempted repairs or service to this
model may render it unfit to use and/or unsafe.
Yamaha Motor Company, Ltd. is continually
striving to improve all models 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.

OE022

EDL20000TE, EDL26000TE

SUPPLEMENTARY SERVICE MANUAL

2002 by Yamaha Motor Co., Ltd.

1st Edition, September 2002
All rights reserved. Any reprinting or
unauthorized use without the written

permission of Yamaha Motor,

Co., Ltd. is expressly prohibited.

Printed in Japan.

HOW TO USE THIS MANUAL

Particularly important information is distin­guished in this manual by the following nota­tions:

The Safety Alert Symbol means ATTENTION!
BE ALERT!
YOUR SAFETY IS INVOLVED!

WARNING

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.

CAUTION:

A CAUTION indicates special precautions that
must be taken to avoid damage to the machine.

NOTE:

A NOTE provides key information that can
make procedures easier or clearer.

MANUAL FORMAT

All of 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 reference
that contains comprehensive explanations of all
inspection, repair, assembly, and disassembly
operations.
If this revised format, the condition of a faulty
component will precede an arrow symbol and
the course of action required to correct the prob­lem will follow the symbol, e.g.,
S Bearings

Pitting/Damage ! Replace.

EXPLODED DIAGRAM

Each chapter provides exploded diagrams be­fore each disassembly section to facilitate cor­rect disassembly and assembly procedures.

CONTENTS

ELECTRICAL

GENERATOR ASSEMBLY 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING OUTPUT VOLTAGE OF STATOR COIL 2. . . . . . . . . . . . .

CHECKING EXCITER FIELD COIL RESISTANCE 3. . . . . . . . . . . . . . .

CHECKING STATOR COIL RESISTANCE 3. . . . . . . . . . . . . . . . . . . . . .

CHECKING OUTPUT VOLTAGE DETECTION CIRCUIT

RESISTANCE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ROTOR FIELD COIL RESISTANCE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXCITER COIL RESISTANCE 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR (EDL20000TE) 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER SOURCE (EDL20000TE) 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR (EDL26000TE) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER SOURCE (EDL26000TE) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL FUNCTION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL BOX 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.C OUTPUT TERMINAL 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PANEL WIRING DIAGRAM (380/ 220 V) 13. . . . . . . . . . . . . . . . . . . . . . .

PANEL WIRING DIAGRAM (220/ 127 V) 14. . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM (380/220 V) 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM (220/127 V) 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM (D.C 12 V) 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR TROUBLESHOOTING 18. . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE CAN BE STARTED AND NO OUTPUT VOLTAGE 18. . .

DIFFICULT TO TAKE OFF OUTPUT VOLTAGE

CONTINUOUSLY 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION

MACHINE IDENTIFICATION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERIAL NUMBER 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING SERIAL NUMBER 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE / LUBRICATION INTERVALS 22. . . . . . . .

SPECIAL TOOLS / TESTERS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TESTERS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PISTON RING COMPRESSOR 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL / FUEL FILTER WRENCH 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EDL20000TE SPECIFICATIONS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SERVICE DATA 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR SERVICE DATA 27. . . . . . . . . . . . . . . . . . . . . . . . . . . .

EDL26000TE SPECIFICATIONS 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SERVICE DATA 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR SERVICE DATA 29. . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM (380-220 V/50Hz) 30. . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAM (220-127 V/60Hz) 32. . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR ASSEMBLY

ELECTRICAL

Order Job/ Part Q’ty Remarks

Disassembling the generator

Bracket

1

2

EX field coil assembly

3

Cover

4

Stator assembly

5

Bearing

6

Rectifier assembly

7

Rotor assembly

1
1
1
1
1
1
1

–1–

CHECKING OUTPUT VOLTAGE
OF STATOR COIL

When the alternator is revolved at 3000
r/min. (50 Hz)/3600 r/min. (60 Hz) with DC
12 V connected on the exciter field coil (F+) –
(F–).

Terminals

(U) – (V)
(V) – (W)
(W) – (U)

(O) – (U)
(O) – (V)
(O) – (W)

Generated voltage

380/220 V model:

Approx. 480 V

220/127 V model:

Approx. 290 V

380/220 V model:

Approx. 277 V

220/127 V model:

Approx. 170 V

CAUTION:

To perform this test, remove A.V.R.

When the alternator is revolved at 3000
r/min. (50 Hz)/3600 r/min. (60 Hz) with
A.V.R and other lead wire disconnected.

Terminals

(U) – (V)
(V) – (W)
(W) – (U)

Generated voltage

380/220 V model:

Approx. 90 V

220/127 V model:

Approx. 50 V

(O) – (U)
(O) – (V)
(O) – (W)

380/220 V model:

Approx. 52 V

220/127 V model:

Approx. 29 V

–2–

CHECKING EXCITER FIELD
COIL RESISTANCE

Check the resistance between (F+) – (F–)
terminals in the control panel.

Resistance (@ 20_C)

24.90 Ω (22.41 X 27.39 Ω)

Out of specification ! Repair wiring or re­place the coil.

CHECKING STATOR COIL
RESISTANCE

Check the resistance between (U) – (V), (V)
– (W), (W) – (U) terminals in the control pan­el.

Resistance (@ 20_C)

EDL20000TE: 0.97 Ω (0.87 X 1.07 Ω)
EDL26000TE: 0.62 Ω (0.55 X 0.69 Ω)

Out of specification ! Repair wiring or re­place the coil.

CHECKING OUTPUT VOLTAGE
DETECTION CIRCUIT
RESISTANCE

Check the resistance between (3) – (4) ter­minals in the control panel.

Resistance (@ 20_C)

EDL20000TE: 0.24 Ω (0.21 X 0.27 Ω)
EDL26000TE: 0.16 Ω (0.14 X 0.18 Ω)

Out of specification ! Repair wiring or re­place stator coil.

ROTOR FIELD COIL
RESISTANCE

Check the resistance between two terminals
on the rotor.

Resistance (@ 20_C)

EDL20000TE: 9.35 Ω (8.42 X 12.24 Ω)
EDL26000TE: 10.90 Ω (9.81 X 14.27 Ω)

–3–

Out of specification ! Replace the rotor as­sembly.

A

EXCITER COIL RESISTANCE

Check the resistance between (U) – (V), (V)
– (W), (W) – (U) terminals on the rotor.

Resistance (@ 20_C)

0.713 Ω(0.64 X 0.79 Ω)

Out of specification ! Replace the rotor as­sembly.

(U) – (V)

A

(V) – (W)

B

(W) – (U)

C

B

C

(U) terminal

1

(V) terminal

2

(W) terminal

3

–4–

GENERATOR (EDL20000TE)

Frequency

Power Source

Unit EDL20000TE

A.C Output:

Rated Voltage

Type Brush-less A.C generator self-exciting

Frequency Hz 50 60

Rated output KVA (kW) 15.5 (12.4) 17.5 (14.0)

Maximum output KVA (kW) 17.0 (13.6) 19.0 (15.2)

Rated voltage V 380/220 220/127

Rated current A 23.6 45.9

Number of pole 2

Phase 3 phase 4 wire

Excitation method Self-excitation with magnetized

Voltage regulator A.V.R. (Automatic Voltage Regulator)

Power factor 0.8

Driving method Direct coupling

Safety device (type) N.F.B. (Non Fuse Breaker)

V 380/220 220/127

N.F.B capacity A 25 45

A.C Output method Terminal

Recommended battery capacity V/Ah 12/65 (65B26R)

Voltage fluctuation % Less than 2.5

Frequency fluctuation % Less than 5

POWER SOURCE (EDL20000TE)

Max. power take off

EDL20000TE

60 Hz 220 V 17500VA

50 Hz 380 V 15500VA

60 Hz 127 V 5800 W

50 Hz 220 V 5100 W

60 Hz 220 V 10000 W

50 Hz 380 V 8900 W

–5–

GENERATOR (EDL26000TE)

Frequency

Power Source

Unit EDL26000TE

A.C Output:

Rated Voltage

Type Brush-less A.C generator self-exciting

Frequency Hz 50 60

Rated output KVA (kW) 21.0 (16.8) 24.0 (19.2)

Maximum output KVA (kW) 23.0 (18.4) 26.0 (20.8)

Rated voltage V 380/220 220/127

Rated current A 31.9 63

Number of pole 2

Phase 3 phase 4 wire

Excitation method Self-excitation with magnetized

Voltage regulator A.V.R. (Automatic Voltage Regulator)

Power factor 0.8

Driving method Direct coupling

Safety device (type) N.F.B. (Non Fuse Breaker)

V 380/220 220/127

N.F.B capacity A 32 63

A.C Output method Terminal

Recommended battery capacity V/Ah 12/70 (75B31R)

Voltage fluctuation % Less than 2.5

Frequency fluctuation % Less than 5

POWER SOURCE (EDL26000TE)

Max. power take off

EDL26000TE

60 Hz 220 V 24000VA

50 Hz 380 V 21000VA

60 Hz 127 V 8000 W

50 Hz 220 V 7000 W

60 Hz 220 V 13800 W

50 Hz 380 V 12000 W

–6–

CONTROL FUNCTION

Fuel tank cap

1

Control box

2

Radiator

3

Oil drain plug

4

Fuel filter

5

Generator assembly

6

Fuel tank

7

Fuel gauge

8

Battery housing

9

10

Battery (Not included in the package)

11

Oil filter

12

Reserve tank

13

A.C output terminal

14

Oil filler cap

15

Exhaust outlet

16

Air filter

17

Fuel cock

–7–

CONTROL BOX

Warning lamp

1

Voltage meter

2

Frequency meter

3

Ampere meter

4

Pilot lamp

5

Key switch

6

Voltage adjuster

7

Hour meter

8

A.C switch (N.F.B)

9

10

A.C output terminals

–8–

Order Job/ Part Q’ty Remarks

Disassembly control box

10
11
12
13
14

1

Panel

2

Panel

3

Panel cover

4

Panel cover

5

Key switch

6

Voltage adjuster

7

A.C switch (N.F.B)

8

Pilot lamp

9

Ampere meter
Frequency meter
Voltage meter
Hour meter
Warning lamp
A.V.R

1
1
1
1
1
1
1
1
1
1
1
1
1
1

–9–