YAMAHA Generator EF6600DE Service Repair Manual

SUPPLEMENTARY SERVICE MANUAL EF6600DE YG6600D YG6600DE 7CC-28197-11 LIT-19616-01-33

HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT IN- FORMATION This material is distinguished by the following notation. Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS IN- VOLVED! w Failure to follow WARNING instructions could result in se v ere injur y or death to the machine operator, a bystander or a person inspecting or repairing the machine. cC 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 reference that contains comprehensive explanations 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., 9 Bearings Pitting/damage → Replace. EXPLODED DIAGRAM Each chapter provides exploded diagrams be- fore each disassembly section for ease in identifying the correct disassembly and assembly procedures. FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the EF6600DE, YG6600D and YG6600DE. For complete information on service procedures, it is necessary to use this Supplementary Service 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 understanding of the mechanical precepts and procedures inherent to generator repair technology. Without such knowl- edge, attempted repairs or service to this model may render it unfit for use and/or unsafe. Yamaha Motor Company Ltd. is continually striv- ing to further 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 ap- plicable, appear in future editions of this manual. EF4600DE, EF6600DE YG4600D, YG6600D, YG6600DE SERVICE MANUAL: 7RH-28197-10 (310062) E. February 1996 LIT-19616-00-73 EF5200DE, EF6600DE YG5200D, YG6600D, YG6600DE SUPPLEMENTARY SERVICE MANUAL: 7WV-28197-10 (310125) E. August 2001 LIT -19616-00-98 EF6600DE, YG6600D, YG6600DE SUPPLEMENTARY SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. 1st Edition, February 2008 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-19616-01-33

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 w are used to identify the specific tools and test equipment. 6 Filling fluid 7 Lubricant 8 Special tool 9 Tightening 0 Wear limit, clearance q Engine speed w Ω, V, A Illustrated symbols e through a in the exploded diagram indicate the grades of lubricant and the locations of the lubrication points. e Apply engine oil r Apply gear oil t Apply molybdenum disulfide oil y Apply wheel bearing grease u Apply lightweight lithium-soap base grease i Apply molybdenum disulfide grease o Apply a locking agent (LOCTITE ® ) p Apply Yamaha bond a Use a new one 1 2 3 4 5 6 7 8 9 0 q w e r t y u i o p a GEN INFO INSP ADJ ENG ñ + 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 PERIODIC INSPECTION AND ADJUSTMENT .............................................................................. 2 CONTROL PANEL ....................................................................................................................... 2 RECEPTACLE ........................................................................................................................ 3 FUEL TANK, CANISTER ............................................................................................................. 4 CANISTER INSTALLATION .................................................................................................... 5 MUFFLER .................................................................................................................................... 6 EXHAUST PIPE AND MUFFLER INSTALLATION .................................................................. 6 ENGINE ........................................................................................................................................... 7 CONTROL BOX ........................................................................................................................... 7 ELECTRICAL .................................................................................................................................. 8 ELECTRICAL COMPONENTS AND CIRCUIT DIAGRAM .......................................................... 8 EF6600DE .............................................................................................................................. 8 EF6600DE .............................................................................................................................. 9 YG6600D .............................................................................................................................. 10 YG6600D .............................................................................................................................. 11 YG6600DE ............................................................................................................................ 12 YG6600DE ............................................................................................................................ 13 ECONOMY IDLE SYSTEM DIAGRAM ..................................................................................... 14 GENERATOR SYSTEM ............................................................................................................. 15 TROUBLESHOOTING CHART ............................................................................................. 15 SPECIFICATIONS ......................................................................................................................... 20 GENERAL SPECIFICATIONS ................................................................................................... 20 MAINTENANCE SPECIFICATIONS .......................................................................................... 22 ENGINE ................................................................................................................................ 22 GENERATOR ........................................................................................................................ 25 ELECTRICAL ........................................................................................................................ 26 TIGHTENING TORQUE ............................................................................................................ 27 GENERAL TORQUE SPECIFICATIONS ................................................................................... 28 DEFINITION OF UNITS ............................................................................................................ 28 WIRE ROUTING DIAGRAM ...................................................................................................... 29 CONTROL BOX PANEL AND BEHIND CONTROL BOX ...................................................... 29 EF6600DE ............................................................................................................................ 29 YG6600D .............................................................................................................................. 30 YG6600DE ............................................................................................................................ 31 CANISTER ............................................................................................................................ 32

1 GEN INFO MACHINE IDENTIFICATION PCC0020 2 GENERAL INFORMATION MACHINE IDENTIFICATION SERIAL NUMBER The serial number is printed at the line 2 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. STARTING SERIAL NUMBER EF6600DE: 7CC-1100101~ YG6600D: 7CC-1130101~ YG6600DE: 7CC-1150101~ NOTE: Designs and specifications are subject to change without notice.

2 INSP ADJ CONTROL PANEL 7 6 6 7 6 7 7 5 1 3 3 2 4 2 9 2 10 9 1 7 8 7 8 1 1 PERIODIC INSPECTION AND ADJUSTMENT CONTROL PANEL Order Job name/Parts name Q’ty Remarks Control panel removal Remove the parts in the order below. 1 Panel cover 1 2 Economy idle switch 1 3 Main Switch 1 4 Oil warning light 1 5 Voltage meter 1 6 AC receptacles 2 7 AC switch(es) 4 8 G.F.C.I receptacles 2 9 Engine switch 1 10 Starter switch 1 For installation, reverse the removal procedure. JOB INSTRUCTION CHART EF6600DE YG6600D YG6600DE YG6600DE/ YG6600D

3 INSP ADJ RECEPTACLE 2 1 RECEPTACLE 1. Check: 9 G.F.C.I. receptacle 1 9 AC receptacle 2 Cracks/damage → Replace. Poor connection → Correct. 1, 2 : 125V, 20 A

4 INSP ADJ FUEL TANK, CANISTER 3 1 2 4 7 Nm (0.7 m•kg,5.1 ft•lb) 7 Nm (0.7 m•kg,5.1 ft•lb) 2 FUEL TANK, CANISTER Order Job name/Parts name Q’ty Remarks Air filter and fuel tank removal Remove the parts in the order below. 1 Fuel hose 1 Turn the fuel petcock to the “C” position. 2 Hose 3 3 Fuel tank 1 4 Canister 1 For installation, reverse the removal procedure. JOB INSTRUCTION CHART

5 INSP ADJ FUEL TANK, CANISTER 1 1 1 CANISTER INSTALLATION 1. Inspect: 9 Hose 1 Cracks/damage → Replace. Poor connection → Correct.

6 ENG MUFFLER 1 2 b 3 a 4 c MUFFLER EXHAUST PIPE AND MUFFLER INSTALLA- TION 1. Install 9 Exhaust gasket 1 1 9 Exhaust gasket 2 2 9 Exhaust pipe 3 9 Muffler assembly 4 NOTE: Tighten the nut a, nut b and bolt c until just comes in contact with the surface, then tighten them further to the specified torque in order of nut a, nut b and bolt c. Nut a 16 Nm (1.6 m · kg, 16.6 ft · lb) Nut b 16 Nm (1.6 m · kg, 16.6 ft · lb) Bolt c 16 Nm (1.6 m · kg, 16.6 ft · lb)

YAMAHA Generator EF6600DE Service Repair Manual

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