Yamaha EF4000DE, EF4600DE, EF6600DE, YG4000D v2 Owner's Manual
en
Generator
LIT-19626-00-98 7WV-28199-10PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 01 908 1.1 1 !
EF4000DE EF5200DE EF6600DE YG4000D YG5200D YG6600D
YG6600DE
OWNERS MANUAL
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7WV-9-10 hyoshi 01.7.31 1:41 PM Page 2
AE00012
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.
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 dig- its are the unit production number. Keep a record of these numbers for reference when ordering parts from a Yamaha deal- er.
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
OWNERS MANUAL 2001 by Yamaha Motor Corporation, U.S.A.
1st Edition, July 2001 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-19626-00-98
MODEL
AE00022
790-060
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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 manu- al, 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.
7WV-9-10 A 01.7.31 1:44 PM Page A-2
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
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1
Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha consumer generators purchased from an authorized Yamaha consumer generator dealer in the continental United States wil l be free from defects in material and workmanship for the period of time stated herein, subject to cer- tain stated limitations.
THE PERIOD OF WARRANTY Any new EF- series or EDL-series Yamaha Generator pur- chased for private, non-commercial use from an authorized Yamaha consumer generator dealer in the continental United States wil l 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 uti l ized for com- mercial or rental applications wil l be war- ranted for a period one hundred eighty (180) days 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 Yamahas option, any part adjudged defec- tive by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs wil l be warranted for the balance of the products warranty period. All parts replaced under warranty become pro- perty 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 gen- uine 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 routine maintenance.
THE CUSTOMERS RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the generator as
specif ied in the appropriate Owners Manual;
2. Give notice to an authorized Yamaha con- sumer generator dealer of any and all ap- parent defects within ten (10) days after discovery, and make the unit available at that t ime for inspection and repairs at such dealers place of business.
WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent purchaser(s), i t is imperative that the unit be inspected and registered for warranty by an authorized Yamaha con- sumer generator dealer. In order for this war- ranty 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 ser- vice. In no case will the warranty be extend- ed beyond the original period.
YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES 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 CONSEQUENTIAL 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
AE00796
YAMAHA MOTOR CORPORATION U.S.A. EF- AND EDL-SERIES GENERATOR LIMITED WARRANTY
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2
Yamaha Motor Corporation, U.S.A. hereby warrants that new Yamaha EC- and YG- series generators purchased from an author- ized Yamaha industrial generator dealer in the continental United States wil l 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 Yamahas option, any part adjudged defec- tive by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs wil l be warranted for the balance of the products warranty period. All parts replaced under warranty become pro- perty 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 gen- uine 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 routine maintenance.
THE CUSTOMERS RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the diesel
generator as specified in the appropriate Owners Manual;
2. Give notice to an authorized Yamaha in- dustrial 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 dealers place of business.
WARRANTY TRANSFER: To transfer the warranty from the original purchaser to any subsequent purchaser(s), i t 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 ser- vice. In no case wil l 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 WARRANTIES 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 CONSEQUENTIAL 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
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3
Q. What costs are my responsibil ity during the warranty period?
A. The customers 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 oi l ; lack of proper maintenance; operating the machine with a broken or damaged part which causes another 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 l imited to repair of the machine itself.
Q. May I perform any or al l of the recommended maintenance shown in the Owners Manual instead of having the dealer do them?
A. Yes, if you are a qualified mechanic and fol low the procedures specif ied in the Owners and Service Manual. We do recommend, however, that i tems 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 specif ied in the Owners 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 Owners 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 addit ion, 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 rere- gistered by an authorized Yamaha generator dealer for the policy to remain effective.
CUSTOMER SERVICE
I f 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, f irst contact the owner of the dealership. Since all warranty matters are handled at the dealer level, this person is in the best posit ion to help you. If you are sti l l not satisfied and require additional assistance, please write:
YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPARTMENT
P.O. BOX 6555 Cypress, California 90630
CHANGE OF ADDRESS
The federal government requires each manufacturer to maintain a complete, up-to- date l ist of al l f irst purchasers against the possibil i ty 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 t ime of your purchase. If you should move after you have purchased your new generator, please advise us of your new address by sending a postcard l ist ing your Yamaha model name, engine number, dealer number (or dealers 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 wil l ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.
WARRANTY QUESTIONS AND ANSWERS
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AE00062
LOCATION OF IMPORTANT LABELS (For EF4000DE/YG4000D) Please read the following labels carefully before oper- ating this machine. NOTE: Maintain or replace safety and instruction labels, as necessary.
1 2
rwt qe y
rwt qy
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 owners 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
SESAE 10W-30 EMISSIONS COMPLIANCE PERIOD:CATEGORY A (EPA)
WARNING READ THE OWNERS MANUAL AND ALL LABELS BEFORE OPERATING.
q qAVERTISSEMENT 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 DEMPLOI ET TOUTES LES ETIQUETTES AVANT DE FAIRE FONCTIONNER LA MACHINE. FAITES FONCTIONNER UNIQUEMENT DANS DES LIEUX BIEN AERES. LES GAZ DECHAPPEMENT CONTIENNENT DU MONOXYDE DE CARBONE. VERIFIEZ SI DU CARBURANT A ETE RENVERSE DU SIL FUIT. ARRETEZ LE MOTEUR AVANT DE FAIRE LE PLEIN DE CARBURANT. NUTILISEZ PAS A PROXIMITE DE MATERIAUX INFLAMMABLES. IL Y A RISQUE DELECTROCUTION SI LE GENERATEUR FONCTIONNE SOUS LA PLUIE, DANS LA NEIGE, OU PRES DE LEAU. GARDEZ LA
4
5
0 2 4 6 8 1 0
ENGINE AIR INDEX ( C a l i f o r n i a o n l y )
LEAST CLEANMOST C L E A N N O T E : T H E L O W E R T H E A I R I N D E X , T H E L E S S T H E P O L L U T I O N
F O R T H E F O L L O W I N G U S E : T H I S E N G I N E I S C E R T I F I E D T O B E E M I S S I O N C O M P L I A N T
MODERATE INTERMEDIATE EXTENDED CHECK OWNERS M A N U A L F O R F U R T H E R D E T A I L S
T H I S L A B E L T O B E R E M O V E D B Y T H E U L T I M A T E P U R C H A S E R O N L Y !
6
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5
(For EF5200DE/EF6600DE/YG5200D/ YG6600D/YG6600DE)
1 2
q e rt
792-027a
qew 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 owners 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
SESAE 10W-30 EMISSIONS COMPLIANCE PERIOD:CATEGORY A (EPA)
WARNING READ THE OWNERS MANUAL AND ALL LABELS BEFORE OPERATING.
q qAVERTISSEMENT 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 DEMPLOI ET TOUTES LES ETIQUETTES AVANT DE FAIRE FONCTIONNER LA MACHINE. FAITES FONCTIONNER UNIQUEMENT DANS DES LIEUX BIEN AERES. LES GAZ DECHAPPEMENT CONTIENNENT DU MONOXYDE DE CARBONE. VERIFIEZ SI DU CARBURANT A ETE RENVERSE DU SIL FUIT. ARRETEZ LE MOTEUR AVANT DE FAIRE LE PLEIN DE CARBURANT. NUTILISEZ PAS A PROXIMITE DE MATERIAUX INFLAMMABLES. IL Y A RISQUE DELECTROCUTION SI LE GENERATEUR FONCTIONNE SOUS LA PLUIE, DANS LA NEIGE, OU PRES DE LEAU. GARDEZ LA
3
4
0 2 4 6 8 1 0
ENGINE AIR INDEX ( C a l i f o r n i a o n l y )
LEAST CLEANMOST C L E A N N O T E : T H E L O W E R T H E A I R I N D E X , T H E L E S S T H E P O L L U T I O N
F O R T H E F O L L O W I N G U S E : T H I S E N G I N E I S C E R T I F I E D T O B E E M I S S I O N C O M P L I A N T
MODERATE INTERMEDIATE EXTENDED CHECK OWNERS M A N U A L F O R F U R T H E R D E T A I L S
T H I S L A B E L T O B E R E M O V E D B Y T H E U L T I M A T E P U R C H A S E R O N L Y !
5
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6
741-002
741-003
741-005
741-004
741- 006
741-007
AE00071
SAFETY INFORMATION
AE00072
EXHAUST FUMES ARE POISONOUS 9 Never 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.
AE00075
FUEL IS HIGHLY FLAMMABLE AND POISONOUS 9 Always turn off the engine when refuelling. 9 Never refuel while smoking or in the vicinity of an
open flame. 9 Take care not to spill any fuel on the engine or
muffler when refuelling. 9 If 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.
9 When operating or transporting the machine, be sure it is kept upright. If it tilts, fuel may leak from the carburetor or fuel tank.
AE00843
ENGINE AND MUFFLER MAY BE HOT 9 Place the machine in a place where pedestrians
or children are not likely to touch the machine.
9 Avoid placing any flammable materials near the exhaust outlet during operation.
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7
741-008a
a
741-009
741-060
q
741-010
741-011
9 Keep the machine at least 1 m (3 ft) from buildings or other equipment, or the engine may overheat.
a 1 m (3 ft)
9 Avoid operating the engine with a dust cover.
9 Be sure to carry the generator only by its carrying handle(s).
1 Carrying handle(s) (shaded)
AE00083
ELECTRIC SHOCK PREVENTION 9 Never operate the engine in rain or snow.
9 Never touch the machine with wet hands or elec- trical shock will occur.
9 Be sure to ground (earth) the generator. NOTE: Use ground (earth) lead of sufficient current capacity.
1 Lead diameter
741-062e
q
A
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8
741-040a
q
w
q
w
EF4000DE/YG4000D B EF5200DE/EF6600DE/YG5200D/YG6600D/YG6600DE
AE00088
CONNECTION NOTES 9 Avoid connecting the generator to commercial power out-
let. 9 Avoid connecting the generator in parallel with any other
generator.
1 Correct 2 Incorrect
AE00086
EXTENSION CORD NOTES 9 When using an extension cord, its total length
should not exceed 60 meters for cross section of 1.5 mm square and 100 meters for cross section of 2.5 mm square.
9 This extension cord should be protected by a tough flexible rubber sheath (IEC 245) or the equivalent to withstand mechanical stresses.
Ground (earth) Lead Diameter:
0.12 mm (0.005 in)/ampere EX;
10 Ampere 1.2mm (0.05 in)
AE00091
CONNECTION
w Before the generator can be connected to a build- ings electrical system, a licensed electrician must install an isolation (transfer) switch in the build- ings 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.
q
741-065
B
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9
AE00101
CONTROL FUNCTION
AE00102
DESCRIPTION (for EF4000DE/EF5200DE/EF6600DE) 1 Fuel tank 2 Fuel tank cap 3 Fuel cock 4 Air filter cover 5 Spark plug 6 Muffler 7 Ground (Earth) terminal 8 Oil filler cap 9 Oil drain plug 0 Recoil starter q Voltage adjuster (for EF5200DE/EF6600DE) w Fuel level gauge e Carrying handles (shaded)
EF4000DE
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EF5200DE/EF6600DE
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10
AE00102
DESCRIPTION (for YG4000D/YG5200D/YG6600D/ YG6600DE) 1 Fuel tank 2 Fuel tank cap 3 Fuel cock 4 Air filter cover 5 Spark plug 6 Muffler 7 Choke lever (for YG4000D/YG5200D/YG6600D) 8 Ground (Earth) terminal 9 Oil filler cap 0 Oil drain plug q Recoil starter w Fuel level gauge e Carrying handles (shaded)
YG4000D
YG6600DE
YG5200D/YG6600D
e q w i
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793-065a
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793-066a
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7WV-9-10 A 01.7.31 1:44 PM Page 10
11
AE00104
CONTROL BOX (for EF4000DE/ EF5200DE/EF6600DE) 1 AC switch (N.F.B.) 2 AC receptacle 3 Voltage meter 4 Oil warning light 5 Engine switch 6 Economy idle switch
EF4000DE
EF5200DE
EF6600DE
q wy er
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w q
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793-067
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12
AE00104
CONTROL BOX (for YG4000D/ YG5200D/YG6600D/ YG6600DE) 1 AC switch (N.F.B.) 2 G.F.C.I. receptacle 3 AC receptacle 4 Voltage meter
(for YG5200D/ YG6600D/YG6600DE)
5 Oil warning light 6 Engine switch 7 Economy idle switch 8 Starter switch
(for YG6600DE) 9 Pilot light
(for YG4000D)
YG4000D
YG5200D
YG6600D
YG6600DE
q w ety u
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q
r w e qt
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u
q
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793-068
r q e qty
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w
793-069
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AE00111
OIL WARNING SYSTEM When the oil level falls below the lower level, the engine stops automatically. Unless you refill with oil, the engine will not start again.
NOTE: If the engine stalls or does not start, turn the engine switch to "ON" position 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.
AE00121
ENGINE SWITCH The engine switch controls the ignition system. 1 7 ON Ignition circuit is switched on. The engine can be started. 2 5 STOP Ignition circuit is switched off. The engine will not run. 3 6 START Starting circuit is switched on. The starter motor starts. EF4000DE/EF5200DE/EF6600DE YG4000D/YG5200D/YG6600D/YG6600DE
cC Take your hand off the switch immediately after the engine starts.
AE00920
STARTER SWITCH (for YG6600DE) The starter switch controls the following item. Push: Starting circuit is switched on. Release: Starting circuit is switched off.
cC Take your hand off the switch immediately after the engine starts.
A
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240V
120V
120V
GR
779-017
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G Y
AE00863
AC SWITCH (N.F.B.) The AC switch (Non-Fuse Breaker) turns off automati- cally when the load exceeds the generator rated out- put.
1 I ON 2 3 OFF EF4000DE/YG4000D EF5200DE/EF6600DE/YG5200D/YG6600D/YG6600DE
Supplies AC 120V (EF4000DE/YG4000D) Supplies AC 120V (EF5200DE/EF6600DE/YG5200D/ YG6600D/YG6600DE) Supplies AC 120V and 240V (EF4000DE/YG4000D) Supplies AC 120V and 240V (EF5200DE/EF6600DE/ YG5200D/YG6600D/YG6600DE)
cC 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.
D-2
D-1
C-2
C-1
AE00142
ECONOMY IDLE SWITCH When the economy idle switch is turned to "ON", the engine speed is automatically reduced to idle when the generator load is reduced to 0.8 A or less. The results are better fuel consumption and less noise.
1 I ON 2 3 OFF
NOTE: The economy idle switch must be turned to "OFF" to increase engine speed to rated rpm when:
- using a load of 0.8 A or less. - supplying AC 120V only from W with X.
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AE00791
VOLTAGE ADJUSTER (for EF5200DE/EF6600DE) The adjuster is equipped for adjusting output voltage to rated voltage.
NOTE: Turn the adjuster clockwise or counterclockwise to increase or decrease output voltage.
AE00848
G.F.C.I. RECEPTACLE (for YG4000D/YG5200D/YG6600D/YG6600DE) The G.F.C.I. (Ground Fault Circuit Interrupter) 1 shuts off power to the protected receptacles if a ground fault (electrical leak) is detected. If the reset button 2 pops out 3, the equipment plugged into the receptacle may be faulty. If this hap- pens, check the equipment carefully. If the equipment 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, unplug the equipment immediately. Have the equipment inspected and repaired by a qualified repairperson before attempting to use it again.
w TO REDUCE THE CHANCE OF ELECTRICAL SHOCK: 9 Do not attempt to operate equipment if the
ground fault circuit interrupter reset button pops out repeatedly during use.
9 Test the ground fault circuit interrupter during the pre-operation checks according to the maintenance instructions on page 35.
9 Remember that only receptacles labeled GFCI have ground fault circuit interrupter protection.
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AE00845
PRE-OPERATION CHECK
NOTE: Pre-operation checks should be made each time the generator is used.
w 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.
AE00856
FUEL Make sure there is sufficient fuel in the tank.
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. 1 Fuel level gauge
Recommended fuel: Unleaded gasoline
Fuel tank capacity: Total:
EF4000DE/YG4000D: 18.5 L (4.07 Imp gal, 4.89 US gal)
EF5200DE/EF6600DE/YG5200D/YG6600D/ YG6600DE:
21.0 L (4.62 Imp gal, 5.55 US gal)
F Full E Empty
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700-068
700-110
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0C 25C
80F32F
A YAMALUBE 4(10W-30)
D SAE 10W C SAE #20 B SAE #30
700-006
w 9 Fuel is highly flammable and poisonous.
Check SAFETY INFORMATION (See page 6) carefully before refueling.
9 Do not fill above the top of the fuel filter or it may overflow when the fuel heats up later and expands.
9 Wipe up any spilled fuel immediately. 9 After refueling, make sure the tank cap is tight-
ened securely.
AE00222
ENGINE OIL Make sure the engine oil is at the upper level of the oil filler hole. Add oil as necessary.
1 Upper level
NOTE: Recommended engine oil classification: API Service SE or SF.
cC The generator has been shipped without engine oil. Fill with oil or it will not start.
Recommended oil: YAMALUBE 4 (10W-30) or SAE 10W-30
type SE motor oil SAE #30 SAE #20 SAE 10W
Engine oil quantity: EF4000DE/YG4000D:
1.0 L (0.88 lmp qt, 1.06 US qt) EF5200DE/EF6600DE/YG5200D/YG6600D/ YG6600DE:
1.1 L (0.97 lmp qt, 1.16 US qt)
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AE00241
GROUND (Earth)
Make sure to ground (earth) the generator. Check "SAFETY INFORMATION" on page 7.
EF4000DE/YG4000D EF5200DE/EF6600DE/YG5200D/YG6600D/YG6600DE
AE00231
BATTERY (for EF4000DE/EF5200DE/EF6600DE/YG6600DE) (See page 34 for more details) Check the fluid level and fill if necessary. Use only distilled water if refilling is necessary. Installation 1. Turn the engine switch to the "STOP" position to
prevent accidental short circuiting. 2. Install the battery on the battery mount tray
securely. NOTE: Clamp the red wire to the positive (+) terminal first, then the black wire to the negative () terminal of the battery. Do not reverse these positions.
w Be sure to service battery leads to prevent arcing when the battery is not installed. 9 Disconnect the battery charging output lead.
Then insulate the generator side connector by folding it back on itself and carefully wraping it with electrical tape to prevent electrical con- tact with ground (earth) or any other leads.
9 Remove the battery leads from the generator.
1 Connector 2 Battery leads 3 Electrical tape
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AE00955
OPERATION NOTE: The generator has been shipped without engine oil. Fill with oil or it will not start.
1 Upper level
AE00918
STARTING THE ENGINE NOTE: 9 Before starting the engine, do not connect any
electric devices. 9 Turn the AC switch (N.F.B.) and economy idle
switch to the OFF position.
1 3 OFF
AC switch (N.F.B.) for EF4000DE/YG4000D AC switch (N.F.B.) for EF5200DE/EF6600DE/YG5200D/
YG6600D/YG6600DE
Economy idle switch
1. Turn the fuel cock lever to the ON position.
1 ON
2. Turn the engine switch to the ON position.
1 7 ON
EF4000DE/EF5200DE/EF6600DE YG4000D/YG5200D/YG6600D/YG6600DE
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Electric Starting Model: (for EF4000DE/EF5200DE/EF6600DE) 3. Turn the engine switch to START.
1 6 START
(for YG6600DE) 3. Push the starter switch to start the engine.
1 Starter switch
cC 9 Take your hand off the switch immediately
after the engine starts. 9 If the engine fails to start, release the switch,
wait a few seconds, then try again. Each attempt should be as short as possible to pre- serve the battery. Do not crank the engine more than 10 seconds on any one attempt.
Manual Starting Model: (for YG4000D/YG5200D/YG6600D) 3. Turn the choke lever to the 1 position.
1 Choke lever
YG4000D YG5200D/YG6600D
NOTE: The choke is not required to start a warm engine. Turn the choke lever to the operating position.
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4. Pull slowly on the recoil starter until it is engaged, then pull it briskly.
5. After the engine starts, warm up the engine until the engine does not stop when the choke lever is returned to the operating position.
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NOTE: Especially in areas below freezing point, keep the choke lever at the halfway position until the engine is warmed up.
6. When the engine is warm, turn the choke lever back to the operating position (fully to the left).
1 Operating position
YG4000D YG5200D/YG6600D
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AE00970
APPLICATION RANGE
AC
Power factor 1 0.80.95 0.40.75
(Efficiency 0.85)
EF4000DE/YG4000D 3,500W 2,800W 1,190W
EF5200DE/YG5200D 4,500W 3,600W 1,530W
EF6600DE YG6600D 6,000W 4,800W 2,040W
YG6600DE
NOTE: 9 means below. 9 Application wattage indicates when each device is used by itself.
cC Be sure the total load is within generator rated output otherwise generator dam- age will occur.
NOTE: Some precision equipment is voltage sensitive and may require a more uniform voltage supply than por