Yamaha EF5200DE - Premium Generator Owner's Manual
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Yamaha EF5200DE - Premium Generator Owner's Manual

Owners manual
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OWNER'S MANUAL
Read this manual carefully before operating this machine.
EF5200DE
EF5200D
LIT-19626-01-76
7CB-F8199-13

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Summary of Contents for Yamaha EF5200DE - Premium Generator

  • Page 1 Generator OWNER’S MANUAL Read this manual carefully before operating this machine. EF5200DE EF5200D LIT-19626-01-76 7CB-F8199-13...
  • Page 2 Read this manual carefully before operating this machine. This manual should stay with this machine if it is sold.
  • Page 3 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.
  • Page 4 If there is any question concerning this manu- al, please consult a Yamaha dealer. A TIP provides key information to make 9 This manual should be considered a procedures easier or clearer.

  • Page 5: Table Of Contents

    EF5200D ..........50 PREPARATION........13 BATTERY TRAY INSTALLATION..51 Fuel.............13 ENGINE HANGER INSTALLATION ..51 Engine oil..........14 OPTIONAL PARTS INSTALLATION..52 Battery installation ......15 YAMAHA MOTOR CORPORATION, PRE-OPERATION CHECK ....17 U.S.A. Pre-operation check ......17 EF SERIES GENERATORS OPERATION..........18 3-YEAR LIMITED WARRANTY....53 Starting the engine ......18 YAMAHA OUTDOOR POWER Stopping the engine......21...

  • Page 6: Safety Information

    SAFETY INFORMATION 9 This generator is not designed for on-board use. Do not use it while installed on the vehicle. 9 Do not modify the generator or use it with its parts removed. 9 Do not allow children to operate the generator. 9 Be sure to carry the generator only by its carrying handle(s).

  • Page 7: Fuel Is Highly Flammable And Poisonous

    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 741-003 muffler when refuelling.

  • Page 8: Electric Shock Prevention

    9 Do not operate the engine with a dust cover or other objects covering it. 9 When covering the generator, be sure to do so only after the engine and muffler have completely cooled down. 7CC-001 Electric shock prevention 9 Never operate the engine in rain or snow. 741-010 9 Never touch the generator with wet hands or elec- trical shock will occur.

  • Page 9: Connection Notes

    Connection notes 9 Avoid connecting the generator to commercial power outlet. 9 Avoid connecting the generator in parallel with any other generator. 1 Correct 2 Incorrect Connection WARNING 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.

  • Page 10: Location Of Important Labels

    The air index of this engine is 3 EMISSION CONTROL INFORMATION (California only) YAMAHA MOTOR POWERED PRODUCTS CO.,LTD. This engine meets 20** California exhaust and evaporative emission regulations for small off-road engines. THIS ENGINE MEETS U.S. EPA EXH EVP REGS FOR 20**.

  • Page 11: Description

    EF5200DE DESCRIPTION 1 Carrying handles (shaded) 2 Fuel tank cap 3 Fuel level gauge 4 Fuel tank 5 Ground (earth) terminal 6 Oil filler cap 7 Oil drain bolt 8 Spark plug 9 Voltage adjuster 0 Fuel cock q Recoil starter w Air filter case cover e Muffler r Choke lever (For EF5200D)

  • Page 12: Control Panel

    EF5200DE Control panel (For EF5200DE) 3 4 5 1 Starter switch 2 Economy control switch 3 Engine switch 4 Oil warning light (red) 5 Voltage meter 6 G.F.C.I. receptacle 7 AC receptacle 8 AC switch (N.F.B.) EF5200D Control panel (For EF5200D) 1 Engine switch 2 Economy control switch...

  • Page 13: Control Function

    CONTROL FUNCTION Engine switch The engine switch controls the ignition system. 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. 763-121 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.

  • Page 14: Ac Switch (N.f.b.)

    å Supplies AC 120 V ∫ Supplies AC 120 V and 240 V NOTICE 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. – 9 –...

  • Page 15: Economy Control Switch

    Economy control switch 1 I “ON” When the economy 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. 763-124 2 3 “OFF” When the economy control switch is turned “OFF”, the engine runs at the rated r/min (3,600 r/min) regardless of whether is a load connected or not.

  • Page 16: G.f.c.i. Receptacle

    G.F.C.I. receptacle WARNING TO REDUCE THE CHANCE OF ELECTRICAL SHOCK: 9 Do not attempt to operate electric devices if the ground fault circuit interrupter reset button 763-083 pops out repeatedly during use. 9 Test the ground fault circuit interrupter during the pre-operation checks according to the maintenance instructions on page 37.

  • Page 17: Fuel Tank Cap

    Fuel tank cap Remove the fuel tank cap by turning it counterclock- wise. 707-051a 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- 7DF-106 tor.

  • Page 18: Preparation

    Fuel tank capacity: Total: 23.0 L (6.08 US gal, 5.06 Imp gal) 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.

  • Page 19: Engine Oil

    Engine oil NOTICE The generator has been shipped without engine oil. Do not start the engine till fill with the suffi- cient engine oil. 700-068 1. Place the generator on a level surface. 2. Remove the oil filler cap. 1 Oil filler cap 3.

  • Page 20: Battery Installation

    Battery installation (For EF5200DE) (See page 35 and 40 for more details) WARNING 9 Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries.
  • Page 21 WARNING 9 Be sure to service battery leads to prevent arc- ing 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 wrapping 762-004 it with electrical tape to prevent electrical con- tact with ground (earth) or any other leads.

  • Page 22: Pre-Operation Check

    9 Check generator for oil leakage. Battery (See page 35) 9 Check the fluid level. 9 Add only distilled water if necessary. The point where abnormality was recognized by use. 9 Check operation. 9 If necessary, consult a Yamaha dealer. – 17 –...

  • Page 23: Operation

    OPERATION WARNING 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 ven- tilated area. 9 Before starting the engine, do not connect any electric devices.
  • Page 24 2. Turn the fuel cock lever to “ON”. 1 “ON” 705-037 3. Turn the engine switch to “ON”. 1 7 “ON” 7CB-013 4. Push the starter switch to start the engine. 1 Starter switch NOTICE 9 Take your hand off the switch immediately 763-011a after the engine starts.
  • Page 25 ∫ Economy control switch 763-126a 2. Turn the fuel cock lever to “ON”. 1 “ON” 705-037 3. Turn the engine switch to “ON”. 1 7 “ON” 763-127f 4. Turn the choke lever to “1”. 1 Choke lever The choke is not required to start a warm engine. Turn the choke lever to the original position.

  • Page 26: Stopping The Engine

    Stopping the engine Turn off any electric devices. 1. Turn the AC switch (N.F.B.) and economy control switch to “OFF”. 1 3 “OFF” å AC switch (N.F.B.) ∫ Economy control switch 763-126a 2. Disconnect any electric devices. 3. Turn the engine switch to “STOP”. 1 5 “STOP”...

  • Page 27: Connection

    Connection Alternating Current (AC) WARNING Be sure any electric devices are turned off before plugging it in. NOTICE 9 Be sure all electric devices including the lines and plug connections are in good condition before connection to the generator. 9 Be sure the total load is within generator rated output.
  • Page 28 NOTICE Reduce the load to the specified generator rated output if an AC switch turns off. If it turns off again, consult a Yamaha dealer. 9 The 4-blade plug receptacle can supply both 120 V and 240 V power sources.

  • Page 29: Application Range

    When using such equipment, consult with a Yamaha dealer. 9 When supplying precision equipment, electronic controllers, PCs, electronic computers, microcomputer-based equipment or battery chargers, keep the generator a sufficient distance away to prevent electrical interference from the engine.

  • Page 30: Periodic Maintenance

    WARNING If you are not familiar with maintenance work, have a Yamaha dealer do it for you. Maintenance chart WARNING Stop the engine before starting maintenance work.
  • Page 31 *1·····Initial replacement of the engine oil is after one month or 20 hours of operation. *2·····The air filter element needs to be replaced more frequently when using in unusually wet or dusty areas. #····· Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser- vice.

  • Page 32: Spark Plug Inspection

    Spark plug inspection The spark plug is important engine components, which should be checked periodically. 1. Remove the spark plug cap and the spark plug. 2. Check for discoloration and remove the carbon. The porcelain insulator around the center elec- trode of spark plug should be a medium-to-light tan color.

  • Page 33: Carburetor Adjustment

    Carburetor adjustment The carburetor is a vital part of the engine. Adjusting should be left to a Yamaha dealer with the profession- al knowledge, specialized data, and equipment to do so properly. Engine oil replacement WARNING Avoid draining the engine oil immediately after stopping the engine.
  • Page 34 6. Add engine oil to the upper level. NOTICE Be sure no foreign material enters the crankcase. 1 Upper level 700-006a 0°C 25°C Recommended engine oil: å YAMALUBE 4 (10W-40), å YAMALUBE 4 (10W-40) SAE 10W-30 or 10W-40 ∫ SAE #30 ∂...

  • Page 35: Air Filter

    Air filter 1. Remove the screws, and then remove the air filter case cover. 2. Remove the foam element. 1 Screws 2 Air filter case cover 3 Foam element 3. Wash the foam element in solvent and dry it. WARNING Never use solvent while smoking or in the vicinity of an open flame.

  • Page 36: Muffler Screen And Spark Arrester

    Muffler screen and spark arrester WARNING 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 741-001 during inspection or repair.
  • Page 37 5. Remove the carbon deposits on the muffler screen and spark arrester using a wire brush. NOTICE When cleaning, use the wire brush lightly to avoid damaging or scratching of the muffler screen and 711-022 spark arrester. 6. Check the muffler screen and spark arrester. Replace them if damaged.

  • Page 38: Fuel Cock

    Fuel cock WARNING Never use the gasoline while smoking 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- 4. Clean the cup and fuel strainer with gasoline and wipe it off.

  • Page 39: Fuel Tank Filter

    Fuel tank filter WARNING Never use the gasoline while smoking or in the vicinity of an open flame. 1. Remove the fuel tank cap and fuel filter. 1 Fuel filter 2. Clean the fuel filter with gasoline. Replace it is damaged. 3.

  • Page 40: Battery

    Battery (For EF5200DE) Replenishing the battery fluid WARNING 9 Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID.

  • Page 41: Recommended Battery

    1. Remove the control panel screws and then remove the control panel. 1 Control panel screws 2. Replace the blown fuse with one of proper amper- age. Specified fuse: 20 A 7CB-011 If the fuse immediately blows again, consult a Yamaha dealer. 779-034b – 36 –...

  • Page 42: G.f.c.i. Receptacle Test

    Incorrect 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. 763-059 WARNING Do not operate the generator with a faulty G.F.C.I. circuit. Electric shock could occur. Have the gen- erator repaired by a qualified mechanic.

  • Page 43: Storage

    STORAGE Long term storage of your generator will require some preventive procedures to guard against deterioration. Drain the fuel 1. Turn the engine switch to “STOP”. 5 “STOP” 2. Remove the fuel tank cap and the fuel filter. Extract the fuel from the fuel tank into an approved gasoline container using a commercially available hand siphon.

  • Page 44: Engine

    6. Drain the fuel remaining in the carburetor into an approved container by loosening the drain screw on the carburetor float chamber. 1 Drain screw 7. Tighten the drain screw. 7CC-016 8. Turn the engine switch to “STOP”. 9. Turn the fuel cock lever to “OFF”. 10.

  • Page 45: Battery

    Battery (For EF5200DE) 1. Remove the battery. 2. Check the fluid level. Add only distilled water if necessary. (See page “BATTERY- Replenishing the battery fluid”) 3. After checking the fluid level, charge the battery. 4. Store the battery in a cool, dark and dry place and 762-003 charge it once a month.

  • Page 46: Troubleshooting

    Poor spark 2 Spark plug dirty with carbon or wet ..Remove carbon or wipe spark plug dry. 2 Faulty ignition system ..Consult a Yamaha deal- 791-001d Generator won’t produce power 2 Safety device (AC switch) to “OFF” ..Turn the AC switch (N.F.B.) to “ON”.
  • Page 47 — MEMO — – 42 –...
  • Page 48 Does not spark Clean Check the following Clogged 9 Fuel line clogging replace W Engine does not start. 9 Air cleaner element clogging. Consult a Yamaha dealer. – 43 –...
  • Page 49 Faulty battery and/or starter motor. Consult a Yamaha dealer. Check engine oil level. Level low Consult a Add engine oil. Yamaha dealer. Check the spark plug. 9 Type: BPR4ES 9 Gap: 0.7–0.8 mm (0.028–0.031 in) Incorrect Replace or Clean the spark adjust gap.
  • Page 50 Replace or Clean the spark hand while testing. adjust gap. plug. Does not spark Clean Check the following O Clogged 9 Fuel line clogging replace Engine does not start. 9 Air cleaner element clogging. Consult a Yamaha dealer. – 45 –...

  • Page 51: Specifications

    SPECIFICATIONS Dimensions Unit EF5200DE EF5200D Overall length mm (in) 894 (35.2) 670 (26.4) Overall width mm (in) 520 (20.5) 510 (20.1) Overall height mm (in) 577 (22.7) 577 (22.7) Dry weight kg (lb) 93 (205) 86 (190) Engine Unit EF5200DE/EF5200D Type Air cooled 4-stroke gasoline OHV Cylinder arrangement...

  • Page 52: Consumer Information

    PRI-I.D. NUMBER: Identification number records Record your Primary I.D., and serial num- bers in the spaces provided, to assist you MODEL in ordering spare parts from a Yamaha dealer. PRI-I.D. Also record and keep these I.D. numbers CODE SERIAL No.

  • Page 53: Exhaust Emission Control

    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 these items be serviced by a Yamaha dealer. – 48 –...

  • Page 54: Wiring Diagram

    WIRING DIAGRAM EF5200DE G Y L/W G Y L/W R/W B G/R G/R 1 Rotor assembly u Condenser Color code Black 2 Exciter field coil i AVR 3 Sub coil o Oil warning unit Brown 4 Main coil p Oil warning light Green Blue 5 Stator assembly...

  • Page 55: Ef5200D

    EF5200D G Y L/W G Y L/W G/R G/R 1 Rotor assembly e Condenser Color code Black 2 Exciter field coil r AVR 3 Sub coil t Oil warning unit Brown 4 Main coil y Oil warning light Green Blue 5 Stator assembly u Economy control unit 6 Voltage meter...

  • Page 56: Battery Tray Installation

    BATTERY TRAY INSTALLATION (For EF5200DE) ENGINE HANGER INSTALLATION – 51 –...

  • Page 57: Optional Parts Installation

    OPTIONAL PARTS INSTALLATION Two wheel kit – 52 –...

  • Page 58: Yamaha Motor Corporation

    Yamaha generator service dealer will, All 1995 and Later EF Models free of charge, repair or replace, at Yamaha’s Two (2) years from the original purchase date option, any part judged defective by Yamaha due to faulty workmanship or material from the factory.
  • Page 59 TIAL 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 – 54 –...
  • Page 60 Yamaha Motor exactly as specified in the Owner’s Manual? Corporation, U.S.A. by the selling dealer at the A. No. The warranty on a new Yamaha cannot time of your purchase. If you should move after be “voided” or “cancelled.”...

  • Page 61: Yamaha Outdoor Power

    If any evaporative emission- coverage, you should contact Yamaha Customer related part on your equipment is defective, the Relations at 1-800-962-7926. part will be repaired or replaced by Yamaha. YAMAHA MOTOR CORPORATION, USA Post Office Box 6555 Cypress, California 90630...

  • Page 62: Yamaha Motor Corporation

    Yamaha recommends that you retain all receipts covering maintenance on your SORE engine, but Yamaha cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
  • Page 63 instructions required by subsection (d) must be warranted for the warranty period defined in Subsection (b)(2). If any such part fails during the period of warranty coverage, it must be repaired or replaced by the manufacturer according to Subsection (4) below. Any such part repaired or replaced under the warranty must be warranted for the remaining warranty period.
  • Page 64 This work must be done at an authorized Yamaha dealer. Give notice to an authorized Yamaha dealer of any apparent defects(s) within a reasonable period of time after discovery. The SORE engine must be made available for inspection by an authorized Yamaha dealer.
  • Page 65 This warranty does not cover damage resulting from accidents, acts of nature, or other events or occur- rences beyond the control of Yamaha. Yamaha Motor Corporation, U.S.A. expressly disclaims responsi- bility for any and all consequential damages, such as loss of time, inconvenience, loss or use of the SORE engine, or commercial loss.

  • Page 66: Yamaha Extended Service (Y.e.s.)

    9 Y.E.S. is flexible. You can choose the plan that’s right for you: 12 months, 24 months or 36 months coverage. 9 Y.E.S. is administered by the same Yamaha people that handle your warranty - and it shows in the comprehensive coverage benefits. There are no hour limitations and Y.E.S. covers manufacturing defects just like your warranty.
  • Page 68 PRINTED IN CHINA 2011.02-0.1×1 ! PRINTED ON RECYCLED PAPER...

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