Yamaha YG5200D User Manual

Generator
7CB-F8199-11
07 9 12 – PDF × 1
!
EF5200DE
YG5200D
OWNER’S MANUAL
LIT-19626-01-49
PLEASE READ AND UNDERSTAND THIS MANUAL
COMPLETELY BEFORE OPERATING THE MACHINE.
7CB-F8199-11_hyoshi 07.12.10 9:26 Page 1
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Yamaha YG5200D Specifications

General

Fuel Type	Gasoline
Frequency	60 Hz
Starting Watts	5200 W
AC Voltage	120/240V
Engine Type	4-Stroke OHV
Engine	Yamaha
Starting System	Electric
Rated AC Amperage	37.5 / 18.8 A

Summary

Introduction

Important Manual Information

Understanding Manual Notations

Explains safety alert symbols, warnings, cautions, and notes for safe and effective operation.

Safety Information

Exhaust Fumes Safety

Warns about poisonous carbon monoxide in exhaust and the need for ventilation.

Fuel Safety Precautions

Covers safe refueling, avoiding ignition sources, and handling spills.

Hot Engine and Muffler Warning

Advises keeping hot engine and muffler away from people and flammable materials.

Generator Safety Practices

Electric Shock Prevention

Details measures to prevent electric shock, including avoiding water and proper grounding.

Operational Safety Guidelines

Covers safe operating distance, avoiding dust covers, and proper carrying methods.

Connection Notes

Generator Connection Guidelines

Provides rules for connecting the generator to power outlets or other generators.

Building Electrical Connections Safety

Crucial safety warning about using licensed electricians and isolation switches for building connections.

Extension Cord Notes

Extension Cord Recommendations

Specifies requirements for extension cords to withstand mechanical stresses.

Important Label Locations

Key Safety and Information Labels

Details critical labels for safety, operation, and emissions information found on the generator.

Generator Description

Component Identification

Identifies key components of the EF5200DE and YG5200D generator models via diagrams and a numbered list.

Control Panel Overview

Control Panel (EF5200DE)

Lists controls for the EF5200DE model, including switches, receptacles, and meters.

Control Panel (YG5200D)

Lists controls for the YG5200D model, including switches, receptacles, and meters.

Control Functions

Engine Switch Operation

Details the function of the engine switch positions: ON, STOP, and START for ignition control.

Oil Warning Light Indicator

Describes the oil warning light's function, activation, and what to do if the engine stalls or doesn't start.

Control Switch Operations

AC Switch (N.F.B.) Operation

Explains how the AC switch (Non-Fuse Breaker) functions and when it might trip due to overload.

Economy Control Switch Function

Details the ON and OFF functions of the economy control switch for fuel efficiency and noise reduction.

Component Adjustments and Features

Voltage Adjuster

Explains the purpose and operation of the voltage adjuster for fine-tuning output voltage.

G.F.C.I. Receptacle Test (YG5200D)

Describes the Ground Fault Circuit Interrupter receptacle and its safety function, including testing.

Generator Components

Fuel Tank Cap

Instructions on how to remove and secure the fuel tank cap.

Fuel Cock Lever

Explains the ON and OFF positions of the fuel cock lever for fuel flow control.

Recoil Starter Operation

Details how to use the recoil starter for both YG5200D and EF5200DE models.

Ground (Earth) Terminal

Explains the function of the ground terminal for preventing electric shock.

Preparation Steps

Fuel Preparation and Safety

Covers fuel type, filling procedure, and safety warnings for handling gasoline.

Checking Fuel Level and Filter

Instructions on checking the fuel level using the gauge and inspecting the fuel filter.

Fuel Specifications and Capacity

Details the recommended fuel type and the generator's fuel tank capacity.

Engine Oil Preparation

Engine Oil Specifications

Lists recommended engine oils, grades, and the required oil quantity based on temperature.

Battery Installation (EF5200DE)

Battery Safety Precautions

Critical warnings about battery electrolyte hazards and necessary safety measures for handling.

Battery Installation Procedure

Step-by-step guide for installing the battery, including connecting terminals and securing the box.

Battery Lead Servicing and Removal

Battery Lead Safety Instructions

Provides safety instructions for servicing battery leads and disconnecting the battery.

Pre-Operation Checks

Fuel System Pre-Check

Checks fuel level and fuel line condition before operating the generator.

Engine Oil Pre-Check

Verifies engine oil level and checks for any oil leakage.

Battery Pre-Check

Instructs to check the battery fluid level and add distilled water if necessary.

General Operation Check

Recommends checking overall generator operation and consulting a dealer if issues arise.

Generator Operation

Electric Starting Procedure (EF5200DE)

Step-by-step guide for starting the EF5200DE model using the electric starter.

Manual Starting Procedure (YG5200D)

Recoil Starter Operation Details

Details the sequence for starting the engine using the recoil starter, including choke and warm-up.

Recoil Starting Procedure Details

Warm-up and Choke Adjustment

Guides on warming up the engine and adjusting the choke lever after starting.

Stopping the Engine

Engine Shutdown Sequence

Provides the correct procedure for safely shutting down the generator engine.

Connecting Electric Devices

AC Power Connection Procedure

Guide to connecting electric devices to the generator, including voltage adjustment.

Powering Electric Devices

Multi-Receptacle and Switch Usage

Details how to connect and power various electric devices, including using different receptacles and switches.

Generator Application Range

Load Capacity and Device Compatibility

Explains generator output ratings, power factors, and compatibility with sensitive electronic equipment.

Periodic Maintenance Overview

Maintenance Schedule Chart

Provides a detailed schedule for inspecting and maintaining generator components at various intervals.

Spark Plug Inspection

Spark Plug Maintenance Procedures

Guides on inspecting, cleaning, checking gap, and torqueing the spark plug for optimal performance.

Maintenance Procedures

Carburetor Adjustment by Dealer

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

Engine Oil Replacement

Details the procedure for draining old engine oil and refilling with new oil.

Air Filter Maintenance

Air Filter Cleaning and Oiling

Instructions for cleaning and oiling the air filter element for proper engine function.

Muffler Screen and Spark Arrester

Cleaning Muffler Components

Guidance on cleaning the muffler screen and spark arrester to maintain performance and prevent damage.

Fuel Cock Maintenance

Fuel Cock Cleaning and Inspection

Procedure for cleaning the fuel cock cup and strainer, and checking the gasket.

Fuel Tank Filter Cleaning

Fuel Filter Maintenance

Instructions on removing, cleaning, and reinstalling the fuel tank filter.

Battery Fluid Replenishment

Battery Fluid Level Check

Details on checking and replenishing the battery fluid level with distilled water.

Fuse and G.F.C.I. Procedures

Fuse Replacement (EF5200DE)

Instructions for replacing a blown fuse in the EF5200DE model, emphasizing correct amperage.

G.F.C.I. Receptacle Test (YG5200D)

Procedure for testing the Ground Fault Circuit Interrupter receptacle on the YG5200D model.

Generator Storage Procedures

Draining Fuel for Storage

Instructions on how to drain the fuel tank and carburetor for long-term storage.

Engine and Battery Storage

Engine Protection for Storage

Steps to protect the engine's internal components from corrosion during storage.

Battery Storage and Charging

Guidance on storing the battery and the recommended frequency for charging it.

Recommended Battery Specifications

Battery Details for EF5200DE

Specifies the recommended battery type and capacity for the EF5200DE model.

Troubleshooting Engine Issues

Engine Won't Start: Fuel System Issues

Troubleshooting steps for fuel system problems preventing the engine from starting.

Engine Won't Start: Oil System Issues

Addresses insufficient engine oil as a cause for the engine not starting.

Engine Won't Start: Electrical Issues

Diagnoses electrical system faults like engine switch, spark plug, or ignition problems.

Engine Won't Start: Compression Issues

Covers compression-related problems such as worn parts or loose cylinder head nuts.

Troubleshooting Power Output Issues (EF5200DE)

Power Output Diagnosis Flowchart

Flowchart to diagnose why the generator is not producing power, covering engine start and component checks.

Troubleshooting Power Output Issues (YG5200D)

Power Output Diagnosis Flowchart (YG5200D)

Flowchart to diagnose why the YG5200D is not producing power, covering engine start and component checks.

Generator Specifications

Dimensional Specifications

Provides physical dimensions and weight specifications for EF5200DE and YG5200D models.

Engine Specifications

Details engine type, displacement, fuel type, oil capacity, spark plug type, and noise level.

Generator Output Specifications

Lists AC output ratings, voltage, frequency, current, and safety device type.

Battery Specifications (EF5200DE)

Specifies the voltage and capacity of the battery used in the EF5200DE model.

Consumer Information

Identification Number Records

Instructions on recording and keeping primary ID, model, and serial numbers for spare parts and security.

Machine Identification Location

Shows the location where the machine serial number is stamped on the generator.

EF/EDL Series Generator Limited Warranty

Warranty Coverage and Exclusions

Details warranty period, what is covered, general and specific exclusions, and customer responsibilities.

Warranty Transfer Procedure

Explains the process and requirements for transferring the generator's warranty to a new owner.

Warranty Disclaimer and Legal Rights

Outlines warranty disclaimers, limitations on implied warranties, and consumer legal rights.

EC/YG Series Generator Limited Warranty

Warranty Coverage and Responsibilities (EC/YG Series)

Covers warranty period, exclusions, and customer duties for EC/YG series generators.

Warranty Transfer for EC/YG Series

Details the process for transferring the warranty for EC/YG series generators.

Warranty Disclaimer and Legal Rights (EC/YG Series)

States disclaimers, limitations, and legal rights concerning EC/YG series generator warranties.

Warranty Questions and Answers

Common Warranty Inquiries

Addresses customer responsibilities, maintenance, voiding warranty, and dealer responsibilities.

Warranty Transferability

Confirms that the warranty is transferable with specific inspection and re-registration procedures.

Customer Service Support

Change of Address Notification

Instructions for owners to notify Yamaha of address changes for safety recall records.

Exhaust Emission Control System

Emission Control Components and Regulations

Lists emission control components, their acronyms, and compliance with US EPA and California regulations.

Wiring Diagram (EF5200DE)

EF5200DE Electrical Schematics

Presents the wiring diagram for the EF5200DE model, including component identification and color codes.

Wiring Diagram (YG5200D)

YG5200D Electrical Schematics

Presents the wiring diagram for the YG5200D model, including component identification and color codes.

Installation of Optional Parts

Battery Tray Installation (EF5200DE)

Illustrates the procedure for installing the battery tray on the EF5200DE generator.

Engine Hanger Installation (YG5200D)

Shows the steps for installing engine hangers on the YG5200D generator.

Two Wheel Kit Installation

Details the installation of a two-wheel kit for the generator.