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Yamaha YG4000D User Manual

Yamaha YG4000D
62 pages
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Generator
LIT-19626-01-15 7WV-28199-11
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
03
9 08 – 1.1 × 1
!
EF4000DE
EF5200DE
EF6600DE
YG4000D
YG5200D
YG6600D
YG6600DE
OWNER’S MANUAL
7WV-9-11 hyoshi 10/15/03 3:47 PM Page 1
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Yamaha YG4000D Specifications

General IconGeneral
ModelYG4000D
Engine Displacement212 cc
Rated AC Voltage120/240V
Frequency60 Hz
Engine Type4-stroke, OHV
Starting SystemRecoil

Summary

INTRODUCTION

PRI-I.D. NUMBER

Field for recording Generator's Primary I.D. Number.

IDENTIFICATION NUMBER RECORDS

Record Primary I.D. and serial numbers for spare parts and theft prevention.

MACHINE IDENTIFICATION

Location of machine serial number and its digits for model identification.

EF- AND EDL-SERIES GENERATOR LIMITED WARRANTY

WARRANTY PERIOD AND EXCLUSIONS

Details warranty duration, general and specific exclusions for EF/EDL series generators.

CUSTOMER RESPONSIBILITY AND TRANSFER

Outlines owner's duties and procedures for warranty transfer.

EC- AND YG-SERIES INDUSTRIAL GENERATOR LIMITED WARRANTY

WARRANTY PERIOD AND EXCLUSIONS

Details warranty duration, general and specific exclusions for EC/YG series generators.

CUSTOMER RESPONSIBILITY AND TRANSFER

Outlines owner's duties and procedures for warranty transfer for EC/YG series.

WARRANTY QUESTIONS AND ANSWERS

CUSTOMER SERVICE AND ADDRESS CHANGE

Provides contact info for customer service and procedures for changing address for warranty registration.

LOCATION OF IMPORTANT LABELS

EF4000DE/YG4000D LABEL LOCATIONS

Identifies and explains important labels on the EF4000DE and YG4000D models.

LOCATION OF IMPORTANT LABELS

EF5200DE/EF6600DE/YG5200D/YG6600D/YG6600DE LABEL LOCATIONS

Identifies and explains important labels on specific generator models.

SAFETY INFORMATION

EXHAUST FUMES HAZARDS

Warns about poisonous exhaust fumes and safe operating conditions.

FUEL HANDLING AND FIRE HAZARDS

Details hazards related to flammable and poisonous fuel and safe refueling practices.

HOT SURFACES WARNING

Alerts users about hot engine and muffler surfaces to prevent burns.

ELECTRIC SHOCK PREVENTION

OPERATING IN WET CONDITIONS

Advises against operating in rain/snow and touching with wet hands to prevent shock.

GROUNDING THE GENERATOR

Explains the importance and method of grounding the generator for safety.

CONNECTION NOTES

AVOIDING COMMERCIAL OUTLET AND PARALLEL CONNECTION

Warns against connecting to commercial outlets or other generators.

CONNECTION

IMPORTANT ELECTRICAL CONNECTION SAFETY

Emphasizes using a licensed electrician for transfer switch installation to prevent backfeeding.

EXTENSION CORD NOTES

PROPER EXTENSION CORD USAGE

Provides guidelines on extension cord length and type for safe generator use.

CONTROL FUNCTION DESCRIPTION

EF4000DE/EF5200DE/EF6600DE CONTROL LAYOUT

Identifies and describes the controls for EF4000DE, EF5200DE, EF6600DE models.

CONTROL FUNCTION DESCRIPTION

YG4000D/YG5200D/YG6600D/YG6600DE CONTROL LAYOUT

Identifies and describes the controls for YG4000D, YG5200D, YG6600D, YG6600DE models.

CONTROL BOX LAYOUT

EF4000DE/EF5200DE/EF6600DE CONTROL PANEL DETAILS

Explains the components and functions of the control box for specific models.

CONTROL BOX LAYOUT

YG4000D/YG5200D/YG6600D/YG6600DE CONTROL PANEL DETAILS

Explains the components and functions of the control box for specific models.

ENGINE SWITCH AND STARTING CONTROLS

OIL WARNING SYSTEM OPERATION

Explains how the oil warning system functions and alerts the user.

ENGINE SWITCH FUNCTIONS

Describes the operation of the engine switch for starting and stopping the engine.

STARTER SWITCH OPERATION

Details the function of the starter switch for the YG6600DE model.

AC SWITCH AND ECONOMY IDLE SWITCH

AC SWITCH (N.F.B.) OPERATION

Explains the function of the AC switch (Non-Fuse Breaker) and its automatic trip mechanism.

ECONOMY IDLE SWITCH FUNCTION

Describes how the economy idle switch improves fuel efficiency and reduces noise.

VOLTAGE ADJUSTER AND G.F.C.I. RECEPTACLE

VOLTAGE ADJUSTER USAGE

Explains how to adjust the output voltage to the rated voltage using the adjuster.

G.F.C.I. RECEPTACLE FUNCTION AND TESTING

Describes the G.F.C.I. receptacle's safety function and how to test it.

PRE-OPERATION CHECK

FUEL LEVEL CHECK

Details the procedure for checking the fuel level and recommended fuel type.

ENGINE OIL MAINTENANCE

RECOMMENDED OIL AND QUANTITY

Specifies recommended engine oil types, classifications, and quantities for different models.

GROUNDING AND BATTERY INSTALLATION

PROPER GROUNDING PROCEDURE

Emphasizes the importance of grounding the generator and refers to safety information.

BATTERY INSTALLATION AND HANDLING

Guides on installing the battery, connecting terminals, and handling precautions.

OPERATION AND STARTING THE ENGINE

GENERAL OPERATION NOTES

Provides initial notes before starting the engine, like filling oil.

STARTING THE ENGINE PROCEDURE

Details the step-by-step process for starting the generator's engine.

STARTING THE ENGINE

ELECTRIC STARTING PROCEDURE

Outlines the steps for starting the engine using the electric start system.

MANUAL STARTING PROCEDURE

Details the steps for starting the engine using the manual recoil starter.

APPLICATION RANGE AND LOAD GUIDELINES

GENERATOR POWER OUTPUT SPECIFICATIONS

Lists the AC power output, power factor, and application wattage for various models.

CONNECTING ALTERNATING CURRENT (AC) DEVICES

AC CONNECTION PROCEDURE AND SAFETY

Guides on connecting AC devices, checking voltage meter, and turning on switches.

AC CONNECTION AND ECONOMY IDLE SWITCH

SPECIAL AC CONNECTION NOTES FOR YG MODELS

Details specific AC switch operations for YG models and 4-blade receptacle usage.

ECONOMY IDLE SWITCH USAGE

Explains when to turn the economy idle switch OFF for optimal engine speed.

STOPPING THE ENGINE

ENGINE SHUTDOWN PROCEDURE

Details the correct steps for safely shutting down the generator engine.

PERIODIC MAINTENANCE

MAINTENANCE CHART AND SCHEDULE

Provides a comprehensive chart detailing maintenance items and their recommended service intervals.

PERIODIC MAINTENANCE

MAINTENANCE ITEMS AND SERVICE INTERVALS

Lists further maintenance items like fuel line, choke lever, cooling system, and their checks.

SPARK PLUG INSPECTION

SPARK PLUG INSPECTION AND REPLACEMENT

Details how to inspect, gap, and torque the spark plug.

CARBURETOR ADJUSTMENT

CARBURETOR ADJUSTMENT RECOMMENDATION

Advises that carburetor adjustment should be performed by a qualified dealer.

ENGINE OIL REPLACEMENT

ENGINE OIL DRAIN AND REFILL PROCEDURE

Guides on draining old oil, replacing the drain plug, and refilling with new oil.

AIR FILTER MAINTENANCE

AIR FILTER CLEANING AND OILING

Details the procedure for cleaning, oiling, and installing the air filter element.

FUEL SYSTEM MAINTENANCE

FUEL COCK CLEANING AND INSPECTION

Explains how to clean and inspect the fuel cock and its components.

FUEL TANK FILTER CLEANING

Details the process for cleaning the fuel tank filter.

MUFFLER SCREEN AND SPARK ARRESTER MAINTENANCE

EF4000DE/YG4000D MUFFLER COMPONENT CLEANING

Guides on removing, cleaning, and inspecting the muffler screen and spark arrester.

MUFFLER SCREEN AND SPARK ARRESTER MAINTENANCE

EF5200DE/EF6600DE/YG5200D/YG6600D/YG6600DE MUFFLER COMPONENT CLEANING

Details cleaning procedures for muffler components on specific models.

MUFFLER SCREEN AND SPARK ARRESTER MAINTENANCE

MUFFLER SCREEN AND SPARK ARRESTER CHECK AND REINSTALLATION

Covers checking for damage, aligning, and reinstalling muffler components.

BATTERY MAINTENANCE

BATTERY FLUID LEVEL CHECK AND REFILLING

Explains how to check and replenish the battery fluid using distilled water.

FUSE REPLACEMENT AND G.F.C.I. TEST

FUSE REPLACEMENT PROCEDURE

Details how to replace a blown fuse with the correct amperage.

G.F.C.I. RECEPTACLE FUNCTIONAL TEST

Guides on testing the Ground Fault Circuit Interrupter receptacle for correct operation.

TROUBLESHOOTING

ENGINE WON'T START DIAGNOSIS

Provides steps to diagnose why the engine may not be starting, covering fuel, oil, and electrical issues.

TROUBLESHOOTING

ENGINE STARTING PROBLEMS FLOWCHART

A flowchart to diagnose engine starting issues for EF/YG models.

TROUBLESHOOTING

ENGINE OIL AND SPARK PLUG CHECK

Guides on checking engine oil level and spark plug condition for troubleshooting.

TROUBLESHOOTING

YG MODEL ENGINE STARTING PROBLEMS FLOWCHART

A flowchart for diagnosing engine starting issues specific to YG models.

STORAGE PREPARATION

DRAIN THE FUEL FOR STORAGE

Details the procedure for draining fuel from the tank and carburetor for long-term storage.

ENGINE PREPARATION FOR STORAGE

Explains how to prepare the engine for storage by oiling the cylinder and cleaning the exterior.

BATTERY STORAGE AND SPECIFICATIONS

BATTERY STORAGE AND CHARGING GUIDELINES

Provides instructions for storing and charging the battery to maintain its condition.

RECOMMENDED BATTERY SPECIFICATIONS

Lists the recommended battery capacity and voltage for the generators.

EXHAUST EMISSION CONTROL SYSTEM

EMISSION CONTROL COMPONENTS AND ACRONYMS

Lists components of the exhaust emission control system and their acronyms.

SPECIFICATIONS

GENERATOR DIMENSIONS AND WEIGHT

Provides physical dimensions and dry weight for various generator models.

ENGINE SPECIFICATIONS

Lists engine type, displacement, bore x stroke, rated output, and fuel capacity.

GENERATOR ELECTRICAL SPECIFICATIONS

Details AC output, voltage, frequency, current, rated output, and safety device type.

EF4000DE WIRING DIAGRAM

EF5200DE WIRING DIAGRAM

EF6600DE WIRING DIAGRAM

YG4000D WIRING DIAGRAM

YG5200D WIRING DIAGRAM

YG6600D WIRING DIAGRAM

YG6600DE WIRING DIAGRAM

ACCESSORY INSTALLATION

BATTERY TRAY INSTALLATION

Provides instructions for installing the battery tray on specific generator models.

ENGINE HANGER INSTALLATION

Guides on installing engine hangers for specific generator models.

OPTIONAL TWO WHEEL KIT INSTALLATION

Details the installation process for the optional two wheel kit.

CUSTOMER WARRANTY REGISTRATION

WARRANTY REGISTRATION FORM INSTRUCTIONS

Explains how to complete and mail the warranty registration form for accurate record-keeping.

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