YAMAHA GeneratorS YG6600DE Owners Manual

Generator LIT-19626-01-15 7WV-28199-11 EF4000DE EF5200DE EF6600DE YG4000D YG5200D YG6600D YG6600DE OWNER’S MANUAL

AE00012 IDENTIFICATION NUMBER RECORDS Record your Primary I.D., and serial numbers in the spaces provided, to assist you in ordering spare parts from a Yamaha dealer. Also record and keep these I.D. numbers in a separate place in case your machine is stolen. AE00011 MACHINE IDENTIFICATION The machine serial number is stamped in the location as shown. NOTE: The first three digits of these numbers are for model identification; the remaining digits are the unit production number. Keep a record of these numbers for reference when ordering parts from a Yamaha dealer. AE00002 INTRODUCTION Congratulations on your purchase of your new Yamaha. This manual will provide you with a good basic understanding of the operation and maintenance of this machine. If you have any questions regarding the operation or maintenance of your machine, please consult a Yamaha dealer. PRI-I.D. NUMBER: PRI-I.D. CODE SERIAL No. EF4000DE/EF5200DE/EF6600DE YG4000D/YG5200D/YG6600D/YG6600DE OWNER’S MANUAL © 2003 by Yamaha Motor Corporation, U.S.A. 1st Edition, August 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan. P/N LIT-19626-01-15 MODEL AE00022 790-060

NOTE: 9 Yamaha continually seeks advance- ments in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your engine and this manual. If there is any question concerning this manual, please consult a Yamaha dealer. 9 This manual should be considered a permanent part of this engine and should remain with this engine when resold. AE00032 w PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE MACHINE. Particularly important information is distin- guished in this manual by the following notations. - The Safety Alert Symbol means ATTEN- TION! BECOME ALERT! YOUR SAFETY IS INVOLVED! w Failure to follow WARNING instructions could result in severe injury or death to the engine operator, a bystander, or a person inspecting or repairing the engine. cC A CAUTION indicates special precautions that must be taken to avoid damage to the engine. NOTE: A NOTE provides key information to make procedures easier or clearer.

AE00041 CONTENTS LIMITED WARRANTY (EF- AND EDL-SERIES) ........................................1 LIMITED WARRANTY (EC- AND YG-SERIES) ..........................................2 LOCATION OF IMPORTANT LABELS.4 SAFETY INFORMATION.......................6 EXHAUST FUMES ARE POISONOUS ......................................6 FUEL IS HIGHLY FLAMMABLE AND POISONOUS ......................................6 ENGINE AND MUFFLER MAY BE HOT ..............................................6 ELECTRIC SHOCK PREVENTION ....7 CONNECTION NOTES ......................8 CONNECTION....................................8 EXTENSION CORD NOTES ..............8 CONTROL FUNCTION ..........................9 DESCRIPTION ...................................9 CONTROL BOX................................11 OIL WARNING SYSTEM ..................13 ENGINE SWITCH .............................13 STARTER SWITCH ..........................13 AC SWITCH (N.F.B.) ........................14 ECONOMY IDLE SWITCH ...............14 VOLTAGE ADJUSTER .....................15 G.F.C.I. RECEPTACLE ....................15 PRE-OPERATION CHECK .................16 FUEL.................................................16 ENGINE OIL .....................................17 GROUND (Earth) ..............................18 BATTERY .........................................18 OPERATION ........................................19 STARTING THE ENGINE.................19 APPLICATION RANGE ....................21 CONNECTION..................................22 STOPPING THE ENGINE ................24 PERIODIC MAINTENANCE ................25 MAINTENANCE CHART ..................25 SPARK PLUG INSPECTION ............27 CARBURETOR ADJUSTMENT .......27 ENGINE OIL REPLACEMENT .........28 AIR FILTER ......................................29 FUEL COCK .....................................30 FUEL TANK FILTER.........................30 MUFFLER SCREEN AND SPARK ARRESTER ......................................31 BATTERY .........................................34 FUSE REPLACEMENT ....................35 G.F.C.I. RECEPTACLE TEST ..........35 TROUBLESHOOTING......................36 STORAGE ...........................................40 DRAIN THE FUEL ............................40 ENGINE ............................................40 BATTERY .........................................41 EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS ...........42 SPECIFICATIONS ...............................43 DIMENSIONS ...................................43 ENGINE ............................................43 GENERATOR ...................................43 WIRING DIAGRAM EF4000DE ........................................44 EF5200DE ........................................45 EF6600DE ........................................46 YG4000D ..........................................47 YG5200D ..........................................48 YG6600D ..........................................49 YG6600DE........................................50 BATTERY TRAY INSTALLATION ......51 ENGINE HANGER INSTALLATION ...51 OPTIONAL PARTS INSTALLATION ..51

– 1 – Yamaha Motor Corporation, U.S.A. hereby war- rants that new Yamaha consumer generators purchased from an authorized Yamaha consumer generator dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations. THE PERIOD OF WARRANTY Any new EF- series or EDL-series Yamaha Generator purchased for private, non-commercial use from an authorized Yamaha consumer generator dealer in the continental United States will be warranted against defects in material or workmanship for a period two (2) years from date of purchase, subject to exclusions noted herein. Any Yamaha non-commercial generator purchased and utilized for commercial or rental applications will be warranted for a period one (1) year from the date of purchase, subject to exclusions noted herein. DURING THE PERIOD OF WARRANTY any authorized Yamaha consumer generator dealer will, free of charge, repair or replace, at Yamaha’s option, any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the product’s warranty period. All parts replaced under warranty become property of Yamaha Motor Corporation U.S.A. GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. b. Abnormal strain, neglect, or abuse. c. Lack of proper maintenance. d. Accident or collision damage. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or rou- tine maintenance. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the generator as specified in the appropriate Owner’s Manual; 2. Give notice to an authorized Yamaha consumer generator dealer of any and all apparent defects within ten (10) days after discovery, and make the unit available at that time for inspection and repairs at such dealer’s place of business. WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent purchaser(s), it is imperative that the unit be inspected and registered for warranty by an authorized Yamaha consumer generator dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service. In no case will the warranty be extended beyond the original period. YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WAR- RANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUEN- TIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. YAMAHA MOTOR CORPORATION, U.S.A. Post Office Box 6555 Cypress, California 90630 AE01119 YAMAHA MOTOR CORPORATION U.S.A. EF- AND EDL-SERIES GENERATOR LIMITED WARRANTY

– 2 – Yamaha Motor Corporation, U.S.A. hereby war- rants that new Yamaha EC- and YG-series generators purchased from an authorized Yamaha industrial generator dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein, subject to certain stated limitations. THE PERIOD OF WARRANTY for Yamaha EC- series and YG-series generators shall be one (1) year from the date of purchase. DURING THE PERIOD OF WARRANTY any authorized Yamaha industrial generator dealer will, free of charge, repair or replace, at Yamaha’s option, any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the product’s warranty period. All parts replaced under warranty become property of Yamaha Motor Corporation U.S.A. GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. b. Abnormal strain, neglect, or abuse. c. Lack of proper maintenance. d. Accident or collision damage. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or rou- tine maintenance. THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the diesel generator as specified in the appropriate Owner’s Manual; 2. Give notice to an authorized Yamaha industrial generator dealer of any and all apparent defects within ten (10) days after discovery, and make the unit available at that time for inspection and repairs at such dealer’s place of business. WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent purchaser(s), it is imperative that the unit be inspected and registered for warranty by an authorized Yamaha industrial generator dealer. In order for this warranty to remain in effect, this inspection and registration must take place within ten (10) days after transfer. An inspection and registration fee will be charged for this service. In no case will the warranty be extended beyond the original period. YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WAR- RANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUEN- TIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. YAMAHA MOTOR CORPORATION, U.S.A. Post Office Box 6555 Cypress, California 90630 YAMAHA MOTOR CORPORATION U.S.A. EC- AND YG-SERIES INDUSTRIAL GENERATOR LIMITED WARRANTY

– 3 – Q. What costs are my responsibility during the warranty period? A. The customer’s responsibility includes all costs of normal maintenance service, non- warranty repairs, accident damages, as well as oil and spark plugs. Q. What are some examples of “abnormal” strain, neglect, or abuse? A. These terms are general and overlap each other in areas. Specific examples include: Running the machine out of oil; lack of proper maintenance; operating the machine with a broken or damaged part which causes anoth- er part to fail; and so on. If you have any specific questions on operation or maintenance, please contact your dealer for advice. Q. Does the warranty cover incidental costs such as transportation due to a failure? A. No. The warranty is limited to repair of the machine itself. Q. May I perform any or all of the recommended maintenance shown in the Owner’s Manual instead of having the dealer do them? A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owner’s and Service Manual. We do recommend, however, that items requiring special tools or equipment be done by a Yamaha generator dealer. Q. Will the warranty be void or cancelled if I do not operate or maintain my new Yamaha exactly as specified in the Owner’s Manual? A. No. The warranty on a new Yamaha cannot be “voided” or “cancelled.” However, if a particular failure is caused by operation or maintenance other than as shown in the Owner’s Manual, that failure may not be covered under warranty. Q. What responsibility does my dealer have under this warranty? A. Each Yamaha generator dealer is expected to: 1. Check the operation of the generator before sale. 2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date. In addition, each Yamaha generator dealer is held responsible for his setup, service and warranty repair work. Q. Is the warranty transferable to second owners? A. Yes. The remainder of the existing warranty can be transfered upon request.The unit has to be inspected and reregistered by an authorized Yamaha generator dealer for the policy to remain effective. CUSTOMER SERVICE If your machine requires warranty service, you must take it to any authorized Yamaha generator dealer within the continental United States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require addi- tional assistance, please write: YAMAHA MOTOR CORPORATION U.S.A. CUS- TOMER RELATIONS DEPARTMENT P.O. BOX 6555 Cypress, California 90630 CHANGE OF ADDRESS The federal government requires each manufac- turer to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety- related defect and recall. This list is compiled from the purchase registrations sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase. If you should move after you have purchased your new generator, please advise us of your new address by sending a post- card listing your Yamaha model name, engine number, dealer number (or dealer’s name) as it is shown on your warranty identification, your name and new mailing address. Mail to: YAMAHA MOTOR CORPORATION, U.S.A. WARRANTY DEPARTMENT P.O. Box 6555 Cypress, California 90630 This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law. WARRANTY QUESTIONS AND ANSWERS

– 4 – AE00062 LOCATION OF IMPORTANT LABELS (For EF4000DE/YG4000D) Please read the following labels carefully before operating this machine. NOTE: Maintain or replace safety and instruction labels, as necessary. 1 2 r w t q e y r w t q y WARNING Electrocution Or property damage can occur: Do not connect this generator to any building ’s electrical system unless an isolation switch has been installed by a licensed elec- trician. Refer to the owner’s manual. HOT EXHAUST 3 WARNING HOT AREA DO NOT TOUCH IMPORTANT ENGINE INFORMATION ENGINE FAMILY : zzzzzzzzzzzz E M REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. THIS ENGINE MEETS zzzz-zzzz CALIFORNIA EMISSION REGULATIONS FOR SMALL OFF-ROAD ENGINES. THIS ENGINE CONFORMS TO PHASE 2 U.S.EPA REGULATIONS FOR SMALL NONROAD ENGINES. YAMAHA MOTOR CO. LTD zzz-2179R-zz DISPLACEMENT: VALVE LASH (A) rpm NO OTHER ADJUSTMENTS NEEDED. ENGINE OIL: IDLE SPEED: FUEL: THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED GASOLINE. IGNITION TIMING & IDLE MIXTURE zzzJ IN: TYPE z.zz~z.zz EX: z.zz~z.zz zzzz~zzzz AT NO LOAD SE SAE 10W-30 EMISSIONS COMPLIANCE PERIOD:CATEGORY A (EPA) WARNING READ THE OWNER‘S MANUAL AND ALL LABELS BEFORE OPERATING. q q AVERTISSEMENT 8 ONLY OPERATE IN WELL-VENTILATED AREA. EXHAUST GAS CONTAINS POISONOUS CARBON MONOXIDE. CHECK FOR SPILLED FUEL OR FUEL LEAKS. STOP ENGINE BEFORE REFUELING. DO NOT OPERATE NEAR FLAMMABLE MATERIALS. ELECTROCUTION CAN OCCUR IF GENERATOR IS USED IN RAIN, SNOW, OR NEAR WATER. KEEP THIS UNIT DRY AT ALL TIMES. 8 8 8 8 8 MACHINE AU SEC EN TOUTES CIRCONSTANCES. 7NJ-24162-10 8 8 8 8 8 8 LISEZ LE MODE D‘EMPLOI ET TOUTES LES ETIQUETTES AVANT DE FAIRE FONCTIONNER LA MACHINE. FAITES FONCTIONNER UNIQUEMENT DANS DES LIEUX BIEN AERES. LES GAZ D‘ECHAPPEMENT CONTIENNENT DU MONOXYDE DE CARBONE. VERIFIEZ SI DU CARBURANT A ETE RENVERSE DU S‘IL FUIT. ARRETEZ LE MOTEUR AVANT DE FAIRE LE PLEIN DE CARBURANT. N‘UTILISEZ PAS A PROXIMITE DE MATERIAUX INFLAMMABLES. IL Y A RISQUE D‘ELECTROCUTION SI LE GENERATEUR FONCTIONNE SOUS LA PLUIE, DANS LA NEIGE, OU PRES DE L‘EAU. GARDEZ LA MACHINE AU SEC EN TOUTES CIRCONSTANCES. 4 5 0 2 4 6 8 10 ENGINE AIR INDEX ( California onl y ) LEAST CLEAN MOST CLEAN NOTE : THE LOWER THE AIR INDEX, THE LESS THE POLLUTION FOR THE FOLLOWING USE: THIS ENGINE IS CERTIFIED TO BE EMISSION COMPLIANT MODERATE INTERMEDIATE EXTENDED CHECK OWNERS MANUAL FOR FURTHER DETAILS THIS LABEL TO BE REMOVED BY THE ULTIMATE PURCHASER ONLY! 6

– 5 – (For EF5200DE/EF6600DE/YG5200D/ YG6600D/YG6600DE) 1 2 qe r t 792-027a q e w t 792-028b WARNING Electrocution Or property damage can occur: Do not connect this generator to any building ’s electrical system unless an isolation switch has been installed by a licensed elec- trician. Refer to the owner’s manual. HOT EXHAUST IMPORTANT ENGINE INFORMATION ENGINE FAMILY : zzzzzzzzzzzz E M REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. THIS ENGINE MEETS zzzz-zzzz CALIFORNIA EMISSION REGULATIONS FOR SMALL OFF-ROAD ENGINES. THIS ENGINE CONFORMS TO PHASE 2 U.S.EPA REGULATIONS FOR SMALL NONROAD ENGINES. YAMAHA MOTOR CO. LTD zzz-2179R-zz DISPLACEMENT: VALVE LASH (A) rpm NO OTHER ADJUSTMENTS NEEDED. ENGINE OIL: IDLE SPEED: FUEL: THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED GASOLINE. IGNITION TIMING & IDLE MIXTURE zzzJ IN: TYPE z.zz~z.zz EX: z.zz~z.zz zzzz~zzzz AT NO LOAD SE SAE 10W-30 EMISSIONS COMPLIANCE PERIOD:CATEGORY A (EPA) WARNING READ THE OWNER‘S MANUAL AND ALL LABELS BEFORE OPERATING. q q AVERTISSEMENT 8 ONLY OPERATE IN WELL-VENTILATED AREA. EXHAUST GAS CONTAINS POISONOUS CARBON MONOXIDE. CHECK FOR SPILLED FUEL OR FUEL LEAKS. STOP ENGINE BEFORE REFUELING. DO NOT OPERATE NEAR FLAMMABLE MATERIALS. ELECTROCUTION CAN OCCUR IF GENERATOR IS USED IN RAIN, SNOW, OR NEAR WATER. KEEP THIS UNIT DRY AT ALL TIMES. 8 8 8 8 8 MACHINE AU SEC EN TOUTES CIRCONSTANCES. 7NJ-24162-10 8 8 8 8 8 8 LISEZ LE MODE D‘EMPLOI ET TOUTES LES ETIQUETTES AVANT DE FAIRE FONCTIONNER LA MACHINE. FAITES FONCTIONNER UNIQUEMENT DANS DES LIEUX BIEN AERES. LES GAZ D‘ECHAPPEMENT CONTIENNENT DU MONOXYDE DE CARBONE. VERIFIEZ SI DU CARBURANT A ETE RENVERSE DU S‘IL FUIT. ARRETEZ LE MOTEUR AVANT DE FAIRE LE PLEIN DE CARBURANT. N‘UTILISEZ PAS A PROXIMITE DE MATERIAUX INFLAMMABLES. IL Y A RISQUE D‘ELECTROCUTION SI LE GENERATEUR FONCTIONNE SOUS LA PLUIE, DANS LA NEIGE, OU PRES DE L‘EAU. GARDEZ LA MACHINE AU SEC EN TOUTES CIRCONSTANCES. 3 4 0 2 4 6 8 10 ENGINE AIR INDEX ( California onl y ) LEAST CLEAN MOST CLEAN NOTE : THE LOWER THE AIR INDEX, THE LESS THE POLLUTION FOR THE FOLLOWING USE: THIS ENGINE IS CERTIFIED TO BE EMISSION COMPLIANT MODERATE INTERMEDIATE EXTENDED CHECK OWNERS MANUAL FOR FURTHER DETAILS THIS LABEL TO BE REMOVED BY THE ULTIMATE PURCHASER ONLY! 5

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YAMAHA GeneratorS YG6600DE Owners Manual

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