Yamaha EF6600DE - Premium Generator User manual

Generator
LIT-19626-01-77
7CC-F8199-15
PRINTED ON RECYCLED PAPER
PRINTED IN CHINA
2011.02-0.1×1 !
(E)
EF6600DE
EF6600D
OWNER’S MANUAL
Read this manual carefully before operating this machine.
7CC-F8199-15_hyoshi 11.2.18 13:21 Page 1

Read this manual carefully before operating this machine. This manual should
stay with this machine if it is sold.
7CC-F8199-15_hyoshi 11.2.18 13:21 Page 3

IDENTIFICATION NUMBER RECORDS
Record your Primary I.D., and serial num-
bers 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.
MACHINE IDENTIFICATION
The machine serial number is stamped in
the location as shown.
TIP
The first three digits of these numbers are
for model identification; the remaining dig-
its are the unit production number. Keep a
record of these numbers for reference
when ordering parts from a Yamaha deal-
er.
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.
EF6600DE/EF6600D
OWNER’S MANUAL
© 2011 by Yamaha Motor Corporation, U.S.A.
1st Edition, February 2011
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in China
P/N LIT-19626-01-77
MODEL
OIL
YAMAHA
OIL
*******
YAMAHA MOTOR POWERED PRODUCTS CO., LTD.
MADE IN CHINA
AC output
Rated
Phase
Fuel
**
Hz
***
kVA
***
V/
***
V
Single
Gasoline
7CC-F8199-15-1 11.2.21 15:55 Page A-1

Particularly important information is distin-
guished in this manual by the following
notations.
This is the safety alert symbol. It is
used to alert you to potential personal
injury hazards. Obey all safety mes-
sages that follow this symbol to avoid
possible injury or death.
A WARNING indicates a hazardous sit-
uation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precau-
tions that must be taken to avoid dam-
age to the machine or other property.
TIP
A TIP provides key information to make
procedures easier or clearer.
NOTICE
WARNING
PLEASE READ AND UNDERSTAND
THIS MANUAL COMPLETELY BEFORE
OPERATING THE MACHINE.
TIP
9Yamaha 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 manu-
al, please consult a Yamaha dealer.
9This manual should be considered a
permanent part of this engine and
should remain with this engine when
resold.
* Product and specifications are subject to
change without notice.
WARNING
7CC-F8199-15-1 11.2.21 15:55 Page A-2

LOCATION OF IMPORTANT
LABELS.................................................1
SAFETY INFORMATION.......................2
EXHAUST FUMES ARE
POISONOUS ......................................2
FUEL IS HIGHLY FLAMMABLE AND
POISONOUS ......................................3
ENGINE AND MUFFLER MAY
BE HOT ..............................................3
ELECTRIC SHOCK PREVENTION....4
CONNECTION NOTES ......................5
CONNECTION....................................5
EXTENSION CORD NOTES ..............5
DESCRIPTION.......................................6
CONTROL PANEL .............................7
CONTROL FUNCTION..........................8
ENGINE SWITCH...............................8
STARTER SWITCH............................8
OIL WARNING LIGHT (red) ...............8
AC SWITCH (N.F.B.) ..........................9
ECONOMY CONTROL SWITCH .....10
VOLTAGE ADJUSTER.....................10
G.F.C.I. RECEPTACLE ....................11
FUEL TANK CAP..............................12
FUEL COCK LEVER ........................12
GROUND (earth) TERMINAL ...........12
PRE-OPERATION CHECK .................13
FUEL.................................................13
ENGINE OIL .....................................15
GROUND (earth) TERMINAL ...........16
BATTERY .........................................16
OPERATION........................................17
STARTING THE ENGINE.................17
APPLICATION RANGE ....................19
CONNECTION..................................20
STOPPING THE ENGINE ................22
PERIODIC MAINTENANCE ................23
MAINTENANCE CHART ..................23
SPARK PLUG INSPECTION............25
CARBURETOR ADJUSTMENT .......25
ENGINE OIL REPLACEMENT .........26
AIR FILTER ......................................28
FUEL COCK .....................................29
FUEL TANK FILTER.........................30
MUFFLER SCREEN AND SPARK
ARRESTER ......................................31
BATTERY .........................................33
RECOMMENDED BATTERY ...........34
FUSE REPLACEMENT ....................34
G.F.C.I. RECEPTACLE TEST ..........35
TROUBLESHOOTING.........................36
STORAGE ...........................................40
DRAIN THE FUEL ............................40
ENGINE ............................................41
BATTERY .........................................42
EXHAUST EMISSION CONTROL
SYSTEM AND COMPONENTS...........43
SPECIFICATIONS ...............................44
DIMENSIONS ...................................44
ENGINE ............................................44
GENERATOR ...................................44
WIRING DIAGRAM..............................45
EF6600DE ........................................45
EF6600D...........................................46
BATTERY TRAY INSTALLATION ......47
ENGINE HANGER INSTALLATION ...47
OPTIONAL PARTS
INSTALLATION...................................48
YAMAHA MOTOR CORPORATION,
U.S.A.
EF SERIES GENERATORS
3-YEAR LIMITED WARRANTY............49
YAMAHA OUTDOOR POWER
EQUIPMENT
CALIFORNIA EVAPORATIVE
EMISSION CONTROL
WARRANTY STATEMENT ..................52
YAMAHA MOTOR CORPORATION,
U.S.A.
SMALL OFF ROAD ENGINES
CALIFORNIA EMISSION
CONTROL WARRANTY.......................53
YAMAHA EXTENDED SERVICE
(Y.E.S.)..................................................57
CONTENTS
7CC-F8199-15-1 11.2.21 15:55 Page A-3

– 1 –
LOCATION OF IMPORTANT LABELS
Please read the following labels carefully before oper-
ating this generator.
TIP
Maintain or replace safety and instruction labels, as
necessary.
1
5
12 34
5421
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.
7DF-F415A-00
WARNING
q
HOT EXHAUST
WARNING
7DF-F4162-10
AVERTISSEMENT
Read the owner’s manual and all labels before operating.
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.
When operating the generator:
Never place a partition or other barrier around the generator.
Do not cover the generator with a box.
Do not place any objects on the generator.
Only operate in well-ventilated areas.
Exhaust gas contains poisonous carbon monoxide.
Lisez le mode d’emploi et toutes les etiquettes avant de
faire fonctionner la machine.
Verifiez si du carburant a ete renverse ou 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 ausec en toutes circonstances.
Quand la génératrice est en marche:
Ne jamais entourer la génératrice de cloisons ou d’écrans.
Ne jamais recouvrir la génératrice d’une boîte.
Ne jamais disposer d’objets sur la génératrice.
Faites fonctionner uniquement dans des lieux bien aeres.
Les gaz d’echappement contiennent du monoxyde de carbone.
2
The air index of this engine is 3
(California only)
MOST CLEAN LEAST CLEAN
0246810
Note: The lower the air index, the less the pollution.
This engine is certified to be emissions compliant
for the following use:
Check owner's manual for further details.
( *** HOURS) ( *** HOURS) ( *** HOURS)
MODERATE INTERMEDIATE EXTENDED
X
EMISSION CONTROL INFORMATION
YAMAHA MOTOR POWERED PRODUCTS CO., LTD.
emission regulations for small off-road engines.
This engine meets 20** California exhaust and evaporative
THIS ENGINE MEETS U.S. EPA EXH EVP REGS FOR 20**.
EVAP F: ********
EF: ***********
EMISSION CONTROL SYSTEM: **
DISPLACEMENT: *** cc
EMISSION COMPLIANCE PERIOD : *** HOURS
This engine is certified to operate on unleaded gasoline.
No other adjustments needed.
ENGINE OIL: SAE***** TYPE : **
4
3
DANGER
Using a generator indoors CAN KILL YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside a home
or garage, EVEN IF doors
and windows are open.
Only use OUTSIDE and
far away from windows,
door, and vents.
7CA-F4877-00
7CC-F8199-15-1 11.2.21 15:55 Page 1

– 2 –
SAFETY INFORMATION
9This generator is not designed for on-board use.
Do not use it while installed on the vehicle.
9Do not modify the generator or use it with its parts
removed.
9Do not allow children to operate the generator.
9Be sure to carry the generator only by its carrying
handle(s).
1Carrying handle(s) (shaded)
9Do not place any obstacles on the generator.
741-060c
1
741-002
EXHAUST FUMES ARE POISONOUS
9Never operate the engine in a closed area or it
may cause unconsciousness and death within a
short time. Operate the engine in a well ventilated
area.
7CC-F8199-15-1 11.2.21 15:55 Page 2

–3 –
741-003
741-005
741-004
741- 006
741-007
FUEL IS HIGHLY FLAMMABLE AND POISONOUS
9Always turn off the engine when refuelling.
9Never refuel while smoking or in the vicinity of an
open flame.
9Take care not to spill any fuel on the engine or
muffler when refuelling.
9Do not leave the generator inside the vehicle or in
the trunk.
9If you swallow any fuel, inhale fuel vapor, or allow
any to get in your eye(s), see your doctor immedi-
ately. If any fuel spills on your skin or clothing,
immediately wash with soap and water and
change your clothes.
9When operating or transporting the generator, be
sure it is kept upright. If it tilts, fuel may leak from
the carburetor or fuel tank.
ENGINE AND MUFFLER MAY BE HOT
9Place the generator in a place where pedestrians
or children are not likely to touch the generator.
9Avoid placing any flammable materials near the
exhaust outlet during operation.
741-008a
a
9Keep the generator at least 1 m (3 ft) from build-
ings or other equipment, or the engine may over-
heat.
a1 m (3 ft)
7CC-F8199-15-1 11.2.21 15:55 Page 3

–4 –
7CC-001
741-010
741-011
9Do not operate the engine with a dust cover or
other objects covering it.
9When covering the generator, be sure to do so
only after the engine and muffler have completely
cooled down.
ELECTRIC SHOCK PREVENTION
9Never operate the engine in rain or snow.
9Never touch the generator with wet hands or elec-
trical shock will occur.
9Connect the ground lead of the generator to the
ground (earth) terminal and connect the end to the
ground electrode buried in the ground.
1Ground (earth) terminal
1
741-128
7CC-F8199-15-1 11.2.21 15:55 Page 4

–5 –
741-040a
1
2
1
2
CONNECTION NOTES
9Avoid connecting the generator to commercial
power outlet.
9Avoid connecting the generator in parallel with any
other generator.
1Correct
2Incorrect
EXTENSION CORD NOTES
Extension cords should be protected by a tough flexi-
ble rubber sheath (IEC 245) or the equivalent to with-
stand mechanical stresses.
CONNECTION
Before the generator can be connected to a build-
ing’s electrical system, a licensed electrician must
install an isolation (transfer) switch in the build-
ing’s main fuse box. The switch is the connection
point for generator power and allows selection of
generator or main line power to the building. This
will prevent the generator from charging the main
power line (backfeeding) when the main power
supply has failed or has been turned off for line
repair. Backfeeding can electrocute or injure line
maintenance personnel. Also, generator and build-
ing electrical system damage can occur when nor-
mal operating power returns if unit is used without
an isolation switch.
WARNING
7CC-F8199-15-1 11.2.21 15:55 Page 5

–6 –
DESCRIPTION
1Carrying handles (shaded)
2Fuel tank cap
3Fuel level gauge
4Fuel tank
5Ground (earth) terminal
6Oil filler cap
7Oil drain bolt
8Spark plug
9Voltage adjuster
0Fuel cock
qRecoil starter
wAir filter case cover
eMuffler
rChoke lever (For EF6600D)
EF6600DE
5
76
23 114
7
11
6
5
4
23
EF6600D
w
9
0
q
e
11
8
w
q
0
9
1
r81
e
7CC-F8199-15-1 11.2.21 15:55 Page 6

–7 –
CONTROL PANEL
(For EF6600DE)
1Starter switch
2Economy control
switch
3Engine switch
4Oil warning light (red)
5Voltage meter
6G.F.C.I. receptacle
7AC receptacle
8AC switch (N.F.B.)
EF6600DE
8
8345216 7
CONTROL PANEL
(For EF6600D)
1Engine switch
2Economy control
switch
3Oil warning light (red)
4Voltage meter
5G.F.C.I. receptacle
6AC receptacle
7AC switch (N.F.B.)
EF6600D
7
34 52167
7CC-F8199-15-1 11.2.21 15:55 Page 7

1
2
763-121
–8 –
700-027c
OIL WARNING LIGHT (red)
When the oil level falls below the lower level, the oil
warning light comes on and then the engine stops
automatically. Unless you refill with oil, the engine will
not start again.
TIP
If the engine stalls or does not start, turn the engine
switch to “ON”and then pull the recoil starter. If the oil
warning light flickers for a few seconds, the engine oil
is insufficient. Add oil and restart.
CONTROL FUNCTION
ENGINE SWITCH
The engine switch controls the ignition system.
17 “ON”
Ignition circuit is switched on.
The engine can be started.
25 “STOP”
Ignition circuit is switched off.
The engine will not run.
STARTER SWITCH (For EF6600DE)
The starter switch controls the following item.
Push:
Starting circuit is switched on.
Release:
Starting circuit is switched off.
Take your hand off the switch immediately after
the engine starts.
NOTICE
763-011
7CC-F8199-15-1 11.2.21 15:55 Page 8

–9 –
AC SWITCH (N.F.B.)
The AC switch (Non-Fuse Breaker) turns off automati-
cally when the load exceeds the generator rated out-
put.
1I“ON”
23“OFF”
åSupplies AC 120 V
∫Supplies AC 120 V and 240 V
Reduce the load to the specified generator rated
output if the AC switch (N.F.B.) turns off. If it turns
off again, consult a Yamaha dealer.
NOTICE
1
2
1
2
1
2
1
1
A
B
7CC-F8199-15-1 11.2.21 15:55 Page 9

–10 –
779-039
779-037
VOLTAGE ADJUSTER
The voltage adjuster is equipped for adjusting output
voltage to rated voltage.
TIP
Turn the voltage adjuster clockwise or counterclock-
wise to increase or decrease output voltage.
1
2
763-124
240V
120V
120V
GR
779-017
WX
G
Y
ECONOMY CONTROL SWITCH
1I“ON”
When the economy control switch is turned to “ON”,
the economy control unit controls the engine speed
according to the connected load. The results are better
fuel consumption and less noise.
23“OFF”
When the economy control switch is turned to “OFF”,
the engine runs at the rated r/min (3,600 r/min) regard-
less of whether there is a load connected or not.
TIP
9The economy control switch must be turned to
“OFF”when using electric devices that require a
large starting current, such as a compressor or a
submergible pump.
9The economy control switch must be turned to
“OFF”to increase engine speed to rated r/min
when:
- using a load of 0.8 A or less.
- supplying AC 120 V only from W with Y.
7CC-F8199-15-1 11.2.21 15:55 Page 10

–11 –
1
2
763-083
3
763-060
G.F.C.I. RECEPTACLE
TO REDUCE THE CHANCE OF ELECTRICAL
SHOCK:
9Do not attempt to operate electric devices if
the ground fault circuit interrupter reset button
pops out repeatedly during use.
9Test the ground fault circuit interrupter during
the pre-operation checks according to the
maintenance instructions on page 35.
9Remember that only receptacle labeled “GFCI”
have ground fault circuit interrupter protec-
tion.
The G.F.C.I. (Ground Fault Circuit Interrupter) shuts
off power to the protected receptacles if a ground fault
(electrical leak) is detected.
If the reset button pops out, the electric devices con-
nected into the receptacle may be faulty. If this hap-
pens, check the electric devices carefully. If the elec-
tric devices appears to be in good condition, press the
reset button firmly until a click is heard. This will
restore power. If the reset button pops out again, dis-
connect all the electric devices immediately. Have the
electric devices inspected and repaired by a qualified
repairperson before attempting to use them again.
1G.F.C.I. (Ground Fault Circuit Interrupter)
2Reset button
3Pops out
WARNING
7CC-F8199-15-1 11.2.21 15:55 Page 11

–12 –
7DF-105
FUEL TANK CAP
Remove the fuel tank cap by turning it counterclock-
wise.
7DF-106
1
2
FUEL COCK LEVER
The fuel cock supplies fuel from the fuel tank to the
carburetor.
The fuel cock has two positions.
1“ON”
With the lever in this position, fuel flows to the carbure-
tor. Normal using is done with the lever in this position.
2“OFF”
With the lever in this position, fuel will not flow. Always
turn the lever to this position when the engine is not
running.
1
741-128
GROUND (earth) TERMINAL
Ground (earth) terminal connects the earth line for pre-
vention of electric shock.
When the electric device is earthed, always the gener-
ator must be earthed.
1Ground (earth) terminal
7CC-F8199-15-1 11.2.21 15:55 Page 12

–13 –
741-001
707-033b
2
707-001
PRE-OPERATION CHECK
Pre-operation checks should be made each time the
generator is used.
The engine and muffler will be very hot after the
engine has been run.
Avoid touching the engine and muffler while they
are still hot with any part of your body or clothing
during inspection or repair.
WARNING
FUEL
Make sure there is sufficient fuel in the tank.
When refueling, be sure to fill the tank to the bottom
edge of the fuel filter.
Your Yamaha engine has been designed to use regu-
lar unleaded gasoline with a pump octane number ((R
+ M)/2) of 86 or higher, or research octane number of
91 or higher.
1Fuel filter
2Fuel level gauge
Recommended fuel:
Unleaded gasoline
Fuel tank capacity:
Total:
23.0 L (6.08 US gal, 5.06 Imp gal)
3“F”Full
4“E”Empty
7DF-020a
43
1
7CC-F8199-15-1 11.2.21 15:55 Page 13

–14 –
9Fuel is highly flammable and poisonous.
Check “SAFETY INFORMATION”(See page 3)
carefully before refueling.
9Do not fill above the top of the fuel filter or it
may overflow when the fuel heats up later and
expands.
9After refueling, make sure the tank cap is tight-
ened securely.
9Immediately wipe off spilled fuel with a clean,
dry, soft cloth, since fuel may deteriorate
painted surfaces or plastic parts.
9Use only unleaded gasoline. The use of leaded
gasoline will cause severe damage to internal
engine parts.
NOTICE
WARNING
707-051
7CC-F8199-15-1 11.2.21 15:55 Page 14

–15 –
700-068b
1
700-110a
2
0°C
åYAMALUBE 4 (10W-40)
∂SAE 10W çSAE #20 ∫SAE #30
32°F
25°C
80°F
700-006
ENGINE OIL
Make sure the engine oil is at the upper level of the oil
filler hole. Add oil as necessary.
1Oil filler cap
2Upper level
The generator has been shipped without engine
oil. Do not start the engine till fill with the suffi-
cient engine oil.
NOTICE
Recommended engine oil:
åYAMALUBE 4 (10W-40),
SAE 10W-30 or 10W-40
∫SAE #30
çSAE #20
∂SAE 10W
Recommended engine oil grade:
API Service SE type or higher
Engine oil quantity:
1.1 L (1.16 US qt, 0.97 Imp qt)
7CC-F8199-15-1 11.2.21 15:55 Page 15