Yamaha EF5200DE - Premium Generator Owner'S Manual Download

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AE00041

CONTENTS

SAFETY INFORMATION

........................1

EXHAUST FUMES ARE

POISONOUS........................................1

FUEL IS HIGHLY FLAMMABLE AND

POISONOUS........................................1

ENGINE AND MUFFLER MAY BE

HOT ......................................................1

ELECTRIC SHOCK PREVENTION......2

CONNECTION NOTES ........................3

CONNECTION .....................................3

EXTENSION CORD NOTES................4

LOCATION OF IMPORTANT LABELS

..5

DESCRIPTION

........................................7

Control Panel........................................8

CONTROL FUNCTION

............................9

Engine switch .......................................9

Oil warning light (red) ...........................9

AC switch (N.F.B.) ..............................10

Economy control switch......................10

Voltage adjuster..................................11

G.F.C.I. receptacle .............................11

Fuel tank cap ......................................12

Fuel cock lever ...................................12

Recoil starter ......................................12

Ground (earth) terminal ......................12

PREPARATION

.....................................13

Fuel.....................................................13

Engine oil............................................14

Battery installation ..............................15

PRE-OPERATION CHECK

...................17

Pre-operation check ...........................17

OPERATION

..........................................18

Starting the engine .............................18

Stopping the engine............................21

Connection .........................................22

Application range................................24

PERIODIC MAINTENANCE

..................25

Maintenance chart ..............................25

Spark plug inspection .........................27

Carburetor adjustment........................28

Engine oil replacement .......................28

Air filter ...............................................29

Muffler screen and Spark arrester ......30

Fuel cock ............................................31

Fuel tank filter .....................................32

Battery ................................................33

Fuse replacement...............................34

G.F.C.I. receptacle test.......................34

STORAGE

.............................................35

Drain the fuel ......................................35

Engine ................................................36

Battery ................................................36

Recommended battery .......................37

TROUBLESHOOTING

..........................38

SPECIFICATIONS

.................................42

Dimensions.........................................42

Engine ................................................42

Generator ...........................................42

Battery ................................................42

CONSUMER INFORMATION

................43

Identification number records .............43

Machine identification .........................43

LIMITED WARRANTY (EF- AND

EDL-SERIES)

........................................44

LIMITED WARRANTY (EC- AND

YG-SERIES)

..........................................45

EXHAUST EMISSION CONTROL

SYSTEM AND COMPONENTS .........47

WIRING DIAGRAM

...............................48

EF5200DE ..........................................48

YG5200D............................................49

Battery tray installation .......................50

Engine hanger installation ..................50

Optional parts installation ...................50

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Summary of Contents for EF5200DE - Premium Generator

Page 1: ...7 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 Downloaded from ManualsNet com search engine ...

Page 2: ...7CB F8199 11_hyoshi 07 12 10 9 26 Page 2 Downloaded from ManualsNet com search engine ...

Page 3: ...n or maintenance of your machine please consult a Yamaha dealer EF5200DE YG5200D OWNER S MANUAL 2007 by Yamaha Motor Corporation U S A 1st Edition December 2007 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 49 AE00022 7CB F8199 11_a 07 12 22 16 30 Page A 1 Downloaded ...

Page 4: ...032 w PLEASE READ AND UNDERSTAND THIS MANUAL COMPLETELY BEFORE OPERATING THE MACHINE 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 consul...

Page 5: ...Connection 22 Application range 24 PERIODIC MAINTENANCE 25 Maintenance chart 25 Spark plug inspection 27 Carburetor adjustment 28 Engine oil replacement 28 Air filter 29 Muffler screen and Spark arrester 30 Fuel cock 31 Fuel tank filter 32 Battery 33 Fuse replacement 34 G F C I receptacle test 34 STORAGE 35 Drain the fuel 35 Engine 36 Battery 36 Recommended battery 37 TROUBLESHOOTING 38 SPECIFICAT...

Page 6: ...e 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 M...

Page 7: ...y 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 Connect the ground lead of the machine to the ground terminal and connect the end to the ground electrode buried in the ground 1 Ground Earth terminal 1 741 128 7CB F8199 11_a 07 12 22 16 30 Page 2...

Page 8: ...n 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 syste...

Page 9: ...ORD NOTES This extension cord should be protected by a tough flexible rubber sheath IEC 245 or the equivalent to withstand mechanical stresses 7CB F8199 11_a 07 12 22 16 30 Page 4 Downloaded from ManualsNet com search engine ...

Page 10: ...IQUETTES AVANT DE FAIRE FONCTIONNER LA MACHINE FAITES FONCTIONNER UNIQUEMENT DANS DES LIEUX BIEN AERES LESGAZD ECHAPPEMENTCONTIENNENTDUMONOXYDEDECARBONE 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 ...

Page 11: ... 6 7CB F8199 11_a 07 12 22 16 30 Page 6 Downloaded from ManualsNet com search engine ...

Page 12: ...cap 6 Oil drain plug 7 Oil filler cap 8 Air filter cover 9 Fuel cock 0 Voltage adjuster q Spark plug w Muffler e Choke lever for YG5200D r Recoil starter EF5200DE 1 7 6 5 4 2 2 3 7 1 6 5 4 2 2 3 YG5200D 8 r 9 2 0 q 2 w 8 9 r 0 2 e q 2 w 7CB F8199 11_a 07 12 22 16 30 Page 7 Downloaded from ManualsNet com search engine ...

Page 13: ...ine switch EF5200DE EF5200DE 0 120 240 4 3 2 1 5 6 AE00104 Control panel for YG5200D 1 AC switch N F B 2 AC receptacle 3 G F C I receptacle 4 Voltage meter 5 Oil warning light 6 Economy control switch 7 Engine switch YG5200D YG5200D 0 120 240 5 4 2 3 1 1 6 7 7CB F8199 11_a 07 12 22 16 30 Page 8 Downloaded from ManualsNet com search engine ...

Page 14: ... light flickers for a few seconds the engine oil is insufficient Add oil and restart AE00101 CONTROL FUNCTION 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 and the engine can be s...

Page 15: ... control switch is turned ON the economy control unit controls the engine speed according to the connected load The results are better fuel consumption and less noise OFF When the economy control switch is turned OFF the engine runs at the rated r min 3 800 r min regardless of whether is a load connected or not 1 I ON 2 3 OFF NOTE The economy control switch must be turned to 3 OFF when using elect...

Page 16: ...page 35 9 Remember that only receptacles labeled GFCI have ground fault circuit interrupter protection 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 appear...

Page 17: ...t flow Always turn the lever to this position when the engine is not running Recoil starter for YG5200D The recoil starter is used for starting the engine for EF5200DE When the engine does not start by electric starter using the recoil starter Pull the recoil starter slowly until it is engaged then pull it briskly Ground earth terminal It is a terminal which connect the earth line for preven tion ...

Page 18: ... plastic parts 9 Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts Recommended fuel Unleaded gasoline Fuel tank capacity Total 23 0 L 5 06 Imp gal 6 08 US gal F Full E Empty 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 1 Fuel level gauge 2 Fuel level 3 Fuel filter Y...

Page 19: ...a level surface 2 Remove the oil filler cap 3 Fill the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 Oil filler cap 2 Upper level Recommended engine oil å YAMALUBE 4 10W 30 or 10W 40 SAE 10W 30 or 10W 40 SAE 30 ç SAE 20 SAE 10W Recommended engine oil grade API Service SE type or higher Engine oil quantity 1 1 L 0 97 lmp qt 1 16 US qt 7CB F8199 11_...

Page 20: ...gases Keep sparks flame cigarettes etc away Ventilate when charging or using in closed space Always cover eyes when working near bat teries KEEP OUT OF REACH OF CHILDREN 1 Fill the battery with the electrolyte Refer to the instruction sheet included with the electrolyte for filling instructions 2 Turn the engine switch to the STOP position to prevent accidental short circuiting 3 Install the batte...

Page 21: ...erator 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 w q 762 004 e q 762 005 7CB F8199 11_a 07 12 22 16 30 Page 16 Downloaded from ManualsNet com search engine ...

Page 22: ...is used Pre operation check Fuel See page 13 9 Check fuel level in fuel tank 9 Refuel if necessary Fuel line 9 Check fuel hose for crack or damage 9 Replace if necessary Engine oil See page 14 9 Check oil level in engine 9 If necessary add recommended oil to specified level 9 Check generator for oil leakage Battery See page 33 9 Check the fluid level 9 Add only distilled water if necessary The poi...

Page 23: ...tric devices cC The generator has been shipped without engine oil Do not start the engine till fill with the suffi cient engine oil AE00918 Starting the engine Erectric Starting for EF5200DE NOTE Turn the AC switch N F B and economy control switch to the OFF position 1 3 OFF å AC switch N F B Economy control switch 1 Turn the fuel cock lever to the ON position 1 ON B A 7CB F8199 11_a 07 12 22 16 3...

Page 24: ...be as short as possible to preserve the bat tery Do not crank the engine more than 10 sec onds on any one attempt 763 127g q 2 Turn the engine switch to the ON position 1 7 ON 763 126a q B Manual Starting for YG5200D NOTE Turn the AC switch N F B and economy control switch to the OFF position 1 3 OFF å AC switch N F B Economy control switch 1 1 A 7CB F8199 11_a 07 12 22 16 30 Page 19 Downloaded fr...

Page 25: ...ever to the original position 3 Turn the engine switch to the ON position 1 7 ON 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 original position 1 Original position 704 010 701 025d q 7CB F8199 11_a 07 12 22 16 30 Page 20 Downloaded from ManualsNet com ...

Page 26: ...E YG5200D 5 Turn the fuel cock lever to OFF 1 OFF 3 Turn the AC switch N F B and economy control switch to the OFF position 1 3 OFF å AC switch N F B AE00840 Stopping the engine 1 Turn off any electric devices 2 Disconnect any electric devices 1 1 A 7CB F8199 11_a 07 12 22 16 30 Page 21 Downloaded from ManualsNet com search engine ...

Page 27: ... earth the generator When the electric device is earthed always the gener ator must be earthed 1 Start the engine 2 Plug in to the AC receptacle 3 Make sure the voltage meter indicates the rated voltage If the voltage meter does not indicate the rated voltage i e when using an extension cord etc use the voltage adjuster to adjust the output volt age to the rated voltage 779 032a q 779 039a A å Vol...

Page 28: ... 240V power sources 9 The economy control switch must be turned to OFF to increase engine speed to rated rpm when using a load of 0 8A or less supplying AC120V only from W with X ç Economy control switch 1 3 OFF 1 5 Turn the individual AC switch N F B to the ON position 1 I ON Individual AC switch EF5200DE YG5200D Individual AC switch YG5200D NOTE The economy control switch must be turned to 3 OFF...

Page 29: ...indicates when each device is used by itself cC Some precision equipment is voltage sensitive and may require a more uniform voltage supply than portable generators provide Examples include some medical equipment personal computers and some inverters that sense peak and RMS voltage values Consult the precision equipment vendor before relying on any portable generator to provide power to such equip...

Page 30: ...onths or 100 Hr 12 months or 300 Hr Spark plug Check condition 1 1 Clean Fuel Check fuel level and leakage 1 Fuel hose Check fuel hose for cracks or damage 1 Engine oil Check oil level in engine 1 Replace 1 1 1 Air filter element Check condition 1 2 1 2 Clean Muffler screen Check muffler screen 1 1 Clean and replace if necessary Spark arrester Check muffler screen 1 1 Clean and replace if necessar...

Page 31: ...n and replace if necessary 1 Battery Check the fluid level 1 Add only distilled water if necessary Crankcase breather Check breather hose for cracks or hose damage 1 Replace if necessary Cylinder head Decarbonize cylinder head More frequently if necessary Valve clearance Check and adjust valve clearance Idle speed Check and adjust idle speed Recoil starter Check recoil starter for damage Fittings ...

Page 32: ...g NOTE If a torque wrench is not available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the specified torque as soon as possible 5 Install the spark plug cap 27 a 760 001a AE00423 Spark plug inspection The spark plug is important engine components which should be checked periodically Standard Spar...

Page 33: ... Oil drain plug 2 Gasket 3 O ring 5 Reinstall the oil drain plug 6 Add engine oil to the upper level 1 Upper level Drain Plug Torque 30 Nm 3 0 m kg 22 ft lb Recommended engine oil å YAMALUBE 4 10W 30 or 10W 40 SAE 10W 30 or 10W 40 SAE 30 ç SAE 20 SAE 10W Recommended engine oil grade API Service SE type or higher Engine oil quantity 1 1 L 0 97 lmp qt 1 16 US qt AE00431 Carburetor adjustment The car...

Page 34: ...hould be wet but not dripping cC Do not wring out the element when squeezing it This could cause it to tear 710 037a Recommended oil Foam air filter oil or SAE 20 motor oil 4 Insert the element into the air filter cC The engine should never run without the element excessive piston and cylinder wear may result NOTE Be sure the element sealing surface matches the air filter case so there is no air l...

Page 35: ...er screen 1 Muffler protector 2 Muffler screen 3 Screw 2 Use a flathead screw driver to pry the spark arrester out from the muffler 711 056 q w e 711 029 q 711 022 711 050 4 Remove the carbon deposits on the muffler screen and spark arrester using a wire brush cC When cleaning use the wire brush lightly to avoid damaging or scratching of the muffler screen and spark arrester 3 Remove the spark arr...

Page 36: ...ear fuel and solvent while smok ing or in the vicinity of an open flame 1 Stop the engine 2 Turn the fuel cock lever to OFF 3 Remove the fuel cock cup gasket and fuel strain er 4 Clean the cup and fuel strainer with gasoline and wipe it off 5 Check the gasket Replace it if damaged 6 Reinstall the fuel strainer gasket and fuel cock cup w Be sure the fuel cock cup is tightened securely 1 Fuel cock c...

Page 37: ...y of an open flame 1 Remove the fuel tank cap and filter 1 Filter 2 Clean the filter with gasoline If damaged replace it 3 Wipe the filter and install it 4 Install the fuel tank cap w Be sure the fuel tank cap is tightened securely 7CB F8199 11_b 07 12 22 10 16 Page 32 Downloaded from ManualsNet com search engine ...

Page 38: ...xplo sive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in closed space Always cover eyes when working near bat teries KEEP OUT OF REACH OF CHILDREN cC 9 Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water 9 Do not disconnect the battery during engine operation 9 Avoid operating the generator with the battery r...

Page 39: ...a dealer AE00501 G F C I receptacle test for YG5200D 1 Start the engine 2 Turn the AC switch N F B to the ON position 3 Press the test button 1 then check the position of the reset button 2 4 If G F C I operation is correct push in the reset button If the G F C I operates incorrectly consult a Yamaha dealer w Do not operate the generator with a faulty G F C I circuit Electric shock could occur Hav...

Page 40: ...d fuel with a clean dry soft cloth since fuel may deteriorate painted sur faces or plastic parts 1 Prepare a container to collect the drained gaso line 2 Drain the fuel from the fuel tank fuel cock and carburetor float bowl a Carburetor drain plug 3 Pour a cup of SAE 10W30 or 20W40 motor oil into the fuel tank 4 Shake the tank to coat the inner surfaces thor oughly 5 Drain off the excess oil 7CB F...

Page 41: ...teps to protect the cylinder pis ton ring etc from corrosion 1 Remove the spark plug pour about one table spoon of SAE 10W30 or 20W40 motor oil into the spark plug hole and reinstall the spark plug Recoil start the engine by turning over several times with ignition off to coat the cylinder walls with oil 2 Pull the recoil starter until you feel compression Then stop pulling This prevents the cylin...

Page 42: ... 37 AE00632 Recommended battery for EF5200DE Recommended battery Capacity 12V 26A h 7CB F8199 11_b 07 12 22 10 16 Page 37 Downloaded from ManualsNet com search engine ...

Page 43: ...ngine oil system Insufficient 2 Oil level is low Add engine oil 3 Electrical systems 2 Engine switch to ON 1 Poor spark 2 Spark plug dirty with carbon or wet Remove carbon or wipe spark plug dry 2 Faulty ignition system Consult dealer 4 Compression Insufficient 2 Worn out piston and cylinder Consult dealer 2 Loose cylinder head nuts Tighten nuts proper ly 2 Damaged gasket Replace gasket 763 127a q...

Page 44: ...ck the spark plug for spark strength See WARNING w 9 To prevent FIRE HAZARDS be sure fuel is not present in the spark plug area 9 To prevent FIRE HAZARDS be sure to place the spark plug as far way as possible from the spark plug hole and car buretor area 9 To prevent ELECTRIC SHOCK do not hold spark plug lead with hand while testing M Engine does not start N Engine starts R Check the following 9 F...

Page 45: ...r E I Check engine oil level J OK K Level low Consult a Yamaha dealer Add engine oil O Check the spark plug 9 Type 9 Gap P Incorrect Q OK Replace or Adjust Gap Clean the spark plug 7CB F8199 11_b 07 12 22 10 16 Page 40 Downloaded from ManualsNet com search engine ...

Page 46: ... HAZARDS be sure to place the spark plug as far way as possible from the spark plug hole and carburetor area 9 To prevent ELECTRIC SHOCK do not hold spark plug lead with hand while testing Engine does not start Engine starts I J Check the following 9 Fuel line clogging 9 Air cleaner element clogging N O Clogged P OK Clean or Replace Consult a Yamaha dealer Q R Consult a Yamaha dealer K Check the s...

Page 47: ...Level dB A 74 0 AE00701 SPECIFICATIONS AE00702 Dimensions Unit EF5200DE YG5200D Overall Length mm in 894 35 2 670 26 4 Overall Width mm in 520 20 5 510 20 1 Overall Height mm in 527 20 8 577 22 72 Dry Weight kg lb 91 201 86 190 AE00704 Engine Measured at rated operation from 7 m 23 ft distance AE00707 Generator Unit EF5200DE YG5200D AC Output Rated voltage V 120 240 Rated frequency Hz 60 Rated cur...

Page 48: ...011 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 PRI I D NUMBER PRI I D CODE SERIAL No MODEL O I L YAMAHA CONSUMER INFORMATION 7CB F8199 11_b 07 1...

Page 49: ...under this warranty shall be to 1 Operate and maintain the generator as speci fied in the appropriate Owner s Manual 2 Give notice to an authorized Yamaha con sumer generator dealer of any and all appar ent defects within ten 10 days after discov ery and make the unit available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warran ty fr...

Page 50: ...e notice to an authorized Yamaha industri al 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 warran ty from the original purchaser to any subsequent purchaser s it is imperative that the unit be inspected and registered for war...

Page 51: ...n 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 own ers 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 SER...

Page 52: ... and the corresponding acronyms are provided in accordance with U S EPA REGULATIONS FOR NEW NONROAD SPARK IGNITION NONHANDHELD ENGINES and the CALIFORNIA REGULATIONS FOR 1995 AND LATER SMALL OFF ROAD ENGINES The acronyms conform to the latest version of the SAE s recommended practice docu ment J1930 Diagnostic Acronyms Terms and Definitions For Electrical Electronic System It is recommended that t...

Page 53: ...olenoid valve f Carburetor heater g Oil level switch h Charging coil j T C I unit k Spark plug l Starter relay Starter motor M V 0 w e r Y Y Y R R R B W B W B W L R L R L R R W R W R W B B B OFF ON START R L R B Y B W R W R R R R L B W L R W B W G R L R L W G R R W B B R G Y L Y G G W B G G Y W B Br G Y L W G Y L W R Y W B B G G B Y R W W B G G L L R G G Y Y Y Y B W Y B W B Y L B W B R W G R B R W...

Page 54: ...l 4 Sub coil 5 Exciter field coil 6 Voltage meter 7 N F B 8 GFCI receptacle 9 AC receptacle 0 Engine switch q Rectifier w AVR Color code B Black Br Brown G Green Gy Gray L Blue R Red W White B W Black White G R Green White G Y Green Yellow L W Blue White R W Red White Y Yellow e Condenser r Economy idle unit t Oil warning unit y Oil warning light u Solenoid valve i Economy control switch o Carbure...

Page 55: ... hanger installation for YG5200D AE00762 Optional parts installation AE00763 Two wheel kit AE00761 Battery tray installation for EF5200DE 7CB F8199 11_b 07 12 22 10 16 Page 50 Downloaded from ManualsNet com search engine ...

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Page 57: ... MEMO 7CB F8199 11_b 07 12 22 10 16 Page 52 Downloaded from ManualsNet com search engine ...

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Page 60: ...7 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 Downloaded from ManualsNet com search engine ...

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