Yanmar Air Cooled,Diesel Generator YDG5001SE

8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE

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OPERATION MANUAL

Y NM R

Y NM R IR COOLED

DIESEL GENER TOR

YDG5 1SE

Be sure to read this manual for safe and

proper operation.Store this manual carefully after use.



1. Handling your generator

YANMAR GENERATOR YDG SERIES

This Operation Manual tells you how to operate and service your new Yanmar generator. Please read it before using the generator toinsure proper handling and operation. Follow the instructionscarefully to keep your engine in the best running condition. If youhave any question concerning this manual, please contact yournearest Yanmar dealer. This Operation Manual deals with the mainpoints for operation of the YDG generator.

In order to insure safe working conditions, be sure to read theprecaution statements

for safe operation of the generator.

Pay special attention to statements preceded by the following words.

WARNING:Indicates a strong possibility of severe personal injury or loss of life ifinstructions are not followed.

A CAUTION:

Indicates a possibility of personal injury or equipment damage ifinstructions are not followed.

Note:Gives helpful information.

If a problem should arise, or if you have any questions about thegenerator contact an authorized Yanmar dealer.

WARNING:The Yanmar generator is designed to give saf e and dependableservice provided that it is operated according to instructions.Read and understand the Operation Manual before operating thegenerator. Failure to do so could result in personal injury orequipment damage.

i




TIPS ON SAFETY

WARNING:

1. PREVENTING FIRES

Never add fuel to the fuel tank while the engine is running.Never add fuel to the fuel tank while smoking or open flame. Do notspill fuel. Wipe away all fuel spills with a clean cloth. Keep gasoline,kerosene, matches and other explosives and inflammables away fromthe generator, because the temperature around the exhaust muffleris very high during operation.

To prevent fire hazards and to provide adequate ventilation,keep the generator at least 3 ft (1 ml away from buildingsand other equipment during operation.

Operate the generator on a level surface. There may be fuelspillage if the generator is tilted.

Do not put the generator indoors while the engine is still hot.

2. PREVENTING EXHAUST GAS INHALATION

Exhaust gas contains poisonous carbon monoxide. Never use the generator in poorly ventilated locations such

as indoors and inside tunnels. When installed in ventilated rooms, additional requirement

for fire and explosion protection are to be abserved.

3. PREVENTING BURNS

Some parts of internal combustion engine are hot and causesburns, pay attention to the warnings on the generator set.

Never touch the muffler, muffler cover or engine body whilethe engine is running or hot.

4. BRAKING

Provide stoppers for the wheels so that the generator will not moveduring operation.

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5. ELECTRIC SHOCKS, SHORT CIRCUITS

In order to avoid electric shocks or short circuiting, do not touch thegenerator when either it or your hands are wet. This generator is notwaterproof, so it should not be used in a place exposed to rain, snowor water sprays. Use of the generator in a wet place can cause shortcircuits and electric shocks during operation.

The generator should be grounded to prevent electricalshocks from faulty appliances. Connect a length of heavywire between the generator’s ground terminal and anexternal ground source.

Do not hook up tools or other apparatus to the generator

before it has been started. If equipment is attached,generator starting may cause sudden movements of theequipment and result in injuries and accidents. Be sure todisconnect any apparatus from the generator prior tostarting.

The generator produces enough electric power to cause aserious shock or electrocution if misissued.

Using a generator or electrical appliance in wet conditions,

such as rain or snow, or near a pool or sprinkler system, or

when your hands are wet, could result in electrocution. Keepthe generator dry.

When the generator is used outdoors, protect it from theweather such as rainfall, snow, etc. Moisture or ice can causea malfunction or short circuit in electrical components whichcould result in electrocution.

Do not connect to a building’s electrical system unless anisolation switch has been installed by a qualified electrician.

CAUTION: Most appliance motors require more than their rated wattage

for start-up. Do not exceed the current limit specified for any one socket.

Do not connect the generator to a household circuit. Thiscould cause damage to the generator and to electricalappliances in the house.

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6. OTHER SAFETY TIPS

Know how to stop the generator quickly and understand howto operate all of the controls. Never permit anyone tooperate the generator without proper instruction.

Always wear suitable clothes when operating its generator.

Do not operate under influence of alcohol. Keep children and pets away from the generator when it is in

operation. Keep away from rotating parts while the generator is

running. A spark arrester is provided as an optional part for this

generator (Standard with U.S. spec. generators). It is illegalin some areas to operate the generator without a sparkarrester. Check local laws and regulations before operatingthe generator.

Work according to the rules and regulations of the workarea.

Use the correct tools and equipment.

7. WHEN CHARGING THE BATTERY

Battery electrolyte contains sulphuric acid. Protect your eyes,skin and clothing. In case of contact, flush thoroughly withwater and get prompt medical attention, especially if youreyes are affected.

Batteries generate hydrogen gas, which can be highlyexplosive. Do not smoke or allow flames or sparks near abattery, especially during charging.

Charge the battery in a fully ventilated location. Be sure to confirm battery polarity, when connecting the

battery.

iv




CONTENST

1. Specification …………………………………………………………. 1

2. Part Names …………………………………………………………… 2

3. Handling your generator ………………………………………… 3

4. Preparation for starting ………………………………………….. 5

5. How to start your generator …………………………………… 12

6. Operating your generator ………………………………………. 14

7. Load ……………………………………………………………………. 15

8. Stopping your generator ……………………………………….. 17

9. Periodic check and maintenance ……………………………. 19

10. Long-term storage ………………………………………………… 25

11. Unclear points or problems …………………………………….. 26

12. Troubleshooting ……………………………………………………. 27

13. How to connect a cable to the Plug Rubber 20A ……... 28

14. Electrical circuit diagram ………………………………………… 29

v



2. Part names1. Specification

1. Specifications

Hz

KVA

Kw

V 220 230 110/220 120/240 110/220

A 19.1 18.3 38.2/191 41.7/20.8 45.5/22.7

rpm

Continous Kw/rpm

rated output (Hp/rpm)

Maximum Kw/rpm

output (Hp/rpm)

cc in

3

l (US qts)

(9.0/3600)

Electric

Diesel fuel

YDG5001SE: 16 (4.22)

406 (24.8)

Forced air-cooled system

Forced lubrication

1.65 (1.74)

6.5/3000

(8.8/3000)

7.3/3600

Revolving field type single-phase alternating current generator

4.2

(10.0/3600)

L100AE-DEGYS 6

5.7/3000

(7.7/3000)

6.6/3600

YDG5001SE

1.0

Single phase

50

4.2

5.0

5.0

60

3000 3600

Fuel oil tank capacity l (US qts)

G e n e r a t o r

2Self-excitation type

Type E

Grease-enclosed

4-cycle single cylinder air cooled diesel engine

L100AE-DEGYS 5

86 x 70 (3.38 x 2.76)

Lubrication system

Lube oil capacity

Starting system

Fuel oil

Cylinder bore x stroke mm (in)

Displacement

Cooling system

Power

Phase

Number of poles Excitation

Insulation

Ball bearing

Type

Model

Output

E n g i n e

Type

Frequency

Rated output

Voltage (AC)

Current (AC)

Revolution speed

Power factor

ModelItem

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2. Part names2. Part Names

2. Part names

2.1. Part names

Exhaust outlet Lifting eye

Fuel Filler capControl panel

Door cabinet

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2. Part Names Part names3. Handling your generator

2.2. Control panel

AC supply lamp Oil alert lamp Voltage meter

Key switch

AC output

Breaker (No-fuse breaker)


3.1. Low oil warning System/Stop Device

The YDG-SE Generators have the Low Oil Warning System/StopDevice (Option for YDG-E models). The device works to stop theengine automatically when the oil pressure falls below the regulatory

level and to prevent engine seizure when lube oil is running short.The oil temperature will rise too high if the engine is operated withinsufficient lube oil. Too much oil, on the other hand is dangerousbecause the oil may combust and cause a sudden and excessive risein engine rpm. So, before operating the generator, be sure to checkthe oil and supply oil to the specified level.

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2. Part Names Part names3. Handling your generator

3.1. How to open the cabinet door and covers

(1)

Opening the cabinet door for daily inspectionTurn the key 900 counterclockwise and pull back the door.

(2) Air cleaner check port cover

Loosen the bolt to open the cover.

Air cleanercheck port cover

3.3. Break-in operation

While your generator is still new, applications of heavy loads

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3. Handling your generator4. Preparation for starting

CAUTION: Only use the recommended diesel fuel oil. Use of non-

recommended fuel may cause clogging in the fuel oilstrainer, fuel injection pump, and fuel injection nozzle.This clogging often causes sudden engine stops afterstarting.

Fuel should have a cetane value of more than 45 in order toprevent difficult starting, misfiring, and white exhaust smoke.

Diesel fuel oil substitutes are not recommended; they maybe harmful to the fuel system components.

Fuel should be free of water or dust because these causetrouble in the fuel injection pump and nozzle.

(3) Do not overfillOverfilling is dangerous. Do not fill the tank beyondthe top of the red plug inside the fuel tank filter.

Fuel tank

capacity

(l )

Upper level

/Lower level

YDG5001SE

16 / 0.5

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WARNING: Refuel in a well-ventilated area with the engine stopped.

Do not smoke or allow flames or sparks in the area wherethe engine is refueled or where gasoline is stored.

Do not overfill the tank. Make sure the filler cap is securelyclosed after refueling.

Be careful not to spill fuel when refueling. If any fuel isspilled, make sure the area is dry before starting the engine.

4.2. Handling your engine oil

WARNING: Always check the lube oil level before starting the engine and

refill if necessary.

The engine may be damaged if operated with insufficientlube oil.

It is also dangerous to supply too much lube oil to the engine

as a sudden increase in engine rpm may be caused by itscombustion.

CAUTION:The YDG-SE series is equipped with a Low Oil WarningSystem/Stop Device (Option for YDG-E models). This safetydevice stops the engine during operation when the oilpressure falls lower than the limit, or the lube oil levelbecomes too low. This prevents accidents such as bearingseizures, etc.

Use the appropriate lube oil in order to preserve yourgenerator.

Nothing affects the performance and durability of yourgenerator more than the lube oil you use. If inferior oil isused, or if your engine oil is not changed regularly, the riskof piston seizure, piston ring sticking and accelerated wear ofthe cylinder liner, bearing and other moving components

increases significantly.

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Your generator’s life may be seriously shortened. Yanmarrecommends CC/CD oil of API engine service classification.

Always use oil with the right viscosity for the ambienttemperature in which your engine is being operated. Use thechart on this page when choosing your engine oil.

Ambient temperature (OC)

40

S.A.E

Service

Grade 5W30

10W

10W30

20W

20W40

20

30

400 10 20 30

5W

-30 -20 -10

Fill the oil up to the filler port with the engine placed on the level.

YDG5001SE

1.65 / 1.05

Lube Oil

capacity

(l )

Upper level

/Lower level

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Oil filler cap / Dipstick

Drain Plug

CAUTION:

When checking the oil level, make sure your generator issifting on the level. If it is tilted, you may add either toomuch or too little oil. If you overfill, your engine will consumetoo much oil. If you do not add enough oil, the oil

temperature will rise dangerously high, and the oil willrapidly degenerate. Engine seizures may also result.So, be sure to check the oil with the engine on a levelsurface and the engine stopped.

To check the oil, simply dip the dipstick into the oil pan. Donot screw in the dipstick.

The YDG-SE models are equipped with an low oil warningSystem/Stop Device, but be sure to check the oil level and torefill with oil to the specified level before starting the

generator.

4.3 Servicing your air cleaner

(1) Loosen the of the air element.Loosen the wing nut, detach the cover cleaner andremove the element.

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Air cleaner

Wing nut

Air cleaner inspectionport cover

Element

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CAUTION: Do not wash the air cleaner element with detergent, because

the element is oil-soaked type. Replace the element when its output decreases or a bad

exhaust color is noticed. Never run the generator without the air cleaner element.

This may cause rapid engine wear.

(2) Reattach the cover of the air cleaner and tighten thewing nut.

4.4. Generator check

Turn off the main switch and any other loads (such as the light andmotor switches).

WARNING:Be sure to turn off the main switch before starting, becauseconnected tools or appliances may become a hazard.

Turn offthe switchdownward

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4. Preparation for starting5. How to start your generator

WARNING:The generator should be earthed to prevent electric shocks.

NOTE:Please observe the panel and use the grounding terminal on

the panel.

5. How to start your generator

WARNING:Do not hook up toots or other apparatus to the generatorbefore it has been started.

5.1. Electric starting

The engine is started in the manner described below.

(1) Starting1). Open the Fuel Cock

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4. Preparation for starting5. How to start your generator

Directionto Open

2). Turn the starting key clockwise to “START”position

Turn the starting key

3). Remove your hand from the key as soon as theengine starts

4). If the engine doesn’t start after 10 seconds, waita while (for about 15 seconds) before attemptingto start again.

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5. How to start your generator

6. Operating your generator

Caution:

If the starting motor is turned for too long, the battery willgo flat. Always leave the starting key turned on, in the “ON”position, while the engine is running.


6.1. Operating your generator

Warm up the engine without load for about 3 minutes.

For generators with low Oil Warning System, check that the Oil AlarmLamp is not lit.

CAUTION: Low Oil Warning System Generators

The blinking of the lube oil alarm lamp is activated by low oilpressure or a lube oil shortage. The engine stopsautomatically. The engine will stop immediately if restartedwithout a lube oil refill. Check the oil level and refill.

Do not loosen or readjust either the engine speed limitingbolt or fuel injection limiting bolt. Performance may beaffected.

Engine speedlimiting bolt

Fuel injectionlimiting bolt

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7. Load

connecting them to the generator. If an appliance begins tooperate abnormally, becomes sluggish, or stops suddenly,turn off the generator main switch immediately. Then dis-connect the appliance and examine it for signs ofmalfunction.

NOTE:

If overloading of the circuit trips the AC circuit protector,reduce ti-re electrical load on the circuit, and Wait a fewminutes before resuming operation.

7.2. DC application

The DC receptacle may be used for charging 12 volt automotive-typebatteries only. (Other loads may not be used.)

Applicable battery: When AC output receptacle is used: 18 - 35 AH (20 hrs.

rating)

When AC output receptacle is not used: 18-60 AH (20hrs. rating)

(1) When using automotive-type batteries with battery cables, besure to disconnect the minus (-) battery cable from the batterybefore charging.

(2) Start the engine

(3) Connect the charging cable to the battery terminals and the DCterminals of the generator.

CAUTION: Connect the positive battery terminal to the positive

generator terminal. Do not reverse the charging cables, orserious damage to the generator and/or battery may occur.

Do not allow the free ends of the cable to touch each other.

If this occurs, it will short circuit the battery.

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7. Load

8. Stopping your generator

When a large capacity battery is charged, excessive current

flows (the value varies depending on the dischargingcondition), and the fuse for the direct current will burnout.

When charging a battery, the total load of the AC and DC

output should not exceed the continuous rated output.

WARNING:

Batteries produce explosive gases. Keep sparks, flames, andcigarettes well away. To prevent the possibility of creating a

spark near the battery, always connect the charging cablesto the battery first and only then to the generator. Whendisconnecting, you should disconnect the cables at thegenerator first.

Charge the battery in a well-ventilated place.

Before charging, remove the cap from each cell of thebattery.

Discontinue charging if the electrolyte temperature exceeds

45°C (117°F).

CAUTION:Do not attempt to start an automobile engine while thegenerator is still connected to the battery. The generatormay be damaged.

CAUTION:

Do not use DC 12 volts and AC at the same time.


(1) Turn off the main switch of the generator.(2) Low Oil Warning System Generator:

With the engine speed lever at “RUN” position, operate the

engine without load for about 3 minutes. Generators w/o Low

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7. Load


Oil warning System:With the engine speed lever at “SLOW” position, operate theengine without load for about 3 minutes.

CAUTION:

Do not stop the engine suddenly because this may cause thetemperature to rise abnormally.

(3) When the key switch is turned to “OFF”, the generator stop.

WARNING:If the engine keeps on running even after the speed lever isplaced at the “STOP” position, either turn the fuel oil cock to

“CLOSE” position (SE type only) or loosen the nut of highpressure fuel pipe on the pump side to stop the engine.In such case, contact your nearest Yanmar to locate thecause and have them e the generator.

Loosen

the nut

CAUTION: Do not stop the engine suddenly because this may cause the

temperature to rise abnormally. Do not stop the engine with the decompression lever.

(4) Set the fuel cock lever to the “S” (closed) position. (SE type only)

- 18 -




9. Periodic checks and maintenance

Closeposition

(5) Slowly pull out the recoil handle until pressure is felt (that is, tothe point in the compression stroke where the intake andexhaust valves are closed), and leave the handle in this position.This prevents rust from forming while the engine is not in use.


Periodic checks and maintenance are very important for keeping thegenerator in good condition and maintenance durability. The chartbelow indicates which checks to make and when to make them. Themark ( ) indicates that special tools and skills are required. Consultyour Yanmar dealer.

WARNING:

Shut off the engine before performing any maintenance. If

the engine must be run, make sure the area is wellventilated. The exhaust contains poisonous carbon monoxidegas.

- 19 -





Maintenance schedule

Check the fuel level Before

and refill if necessary

Once

Replace the fuel filter

element

Check for fuel oil After

leakage

Fuel injection Check the injection

Bozzle condition

Check the lube. Oil level in the oil Before

pan and refill if necessary

2nd time

2nd time

After

Air

induction

System

Electric Check the battery liquid level Before

System and refill if necessary

Engine Adjusting the intake and exhaust

Body valve clearance

Check commutator brush

and slip ring

& thereafter

a month

1st time

1st time

& thereafter

Operation

Operation

Operation

Operation

or everyevery 200hrs every 400hrs 1000hrs

Daily check

Every month

or every50hrs

Every 3 Every 6 Every year

month or month or

Operation

Check the air cleaner element

Replace the air cleaner element

Generator

Part Item

F u e l O i l S y s t e m

Replace the lube. Oil

Clean lube. Oil filter

Check for lube. Oil leakage L u b e .

O i l S y s t e m

Drain the fuel tank

Clean the fuel tank

Check the fuel injection timing

Check the fuel injection pump

NOTE: Item marked ( ) should be serviced by an authorized

Yanmar dealer, unless the owner proficient mechanical ability and

the proper tools.

CAUTION: After the engine has been used, clear it immediately with a

cloth to prevent corrosion and to remove sediment. Use only genuine Yanmar parts. The use of replacement

parts, which are not of equivalent quality, may damage theengine.

- 20 -



8. Stopping your generator9. Periodic checks and maintenance

9.1. How to change your engine oil

Remove the oil filler cap. Remove the tam plug and drain the old oilwhile tie engine is still warm. The plug is located on the bottom ofthe cylinder Sock. Tighten the drain plug and refill with therecommended oil, (See the section under “Preparations for starting.”)


Drain Plug

9.2. Cleaning the oil filter

Loosen the fixing bolt and then pull out the oil filter.

Cleaning Every 6 months or

time 400 hours

Replace if necessary

- 21 -




Oil filter

9.3. Changing the air cleaner element

Do not wash the air cleaner element with detergent because this is aoil-soaked type element.

Every 6 months or

400 hours(or earlier if dirty)

Change

Element

See the section for changing the air cleaner element under

“Preparations for starting.”

- 22 -




CAUTION:Never run the engine without the element or with a defectiveelement.

Note: A clogged element hinders the flow of air to the combustion

chamber. This reduces engine output, increases lube oil andfuel oil consumption and makes starting difficult.

Make sure you replace your element regularly.

9.4. Cleaning and replacing the fuel filter

The fuel filter also has to be cleaned regularly to insure maximumengine output.

Every 3 months or

200 hours

Every 6 months or

400 hoursReplace

Clean

Fuel tank

Release the fuel intakeHose’s to drain the fuel tank

(1) Drain the fuel oil from the fuel tank by releasing the fuel intakehose’ s.

- 23 -




(2) Loosen the small screws of the fuel cock and pull out the filterfrom the F.O. tank. Wash the filter thoroughly with diesel fuel.

9.5. Checking the injection nozzle. Injection pump, etc.

Adjusting the valve head clearance for the intake andexhaust valves.

This requires special tools and skills, so contact your Yanmardealer.

WARNING:Do not perform the injection nozzle test near an open fire orany other kind of fire, The fuel spray may ignite. Do not bareskin to the fuel spray. The fuel may penetrate the skin andcause injury to the body. Always keep your body away fromthe nozzle.

9.6. Charging the battery

WARNING: Before charging, remove the cap from each cell of the

battery.

Charge the battery in a place where there is plenty ofventilation.

Discontinue charging if the electrolyte temperature exceeds45°C (117° F).

CAUTION:

Do not charge the battery with the battery cable stillconnected. The high voltage will damage the diodes.

Connect the (+) lead of the charger to the (+) terminal ofthe battery, and the (—) lead to the (—) terminal. Reversedpolarity will damage the charger rectifier or the battery.

After charging is completed, connect the battery cablescorrectly to the battery. Reversed polarity wiring will damage

the diodes.

- 24 -



9. Periodic checks and maintenance10. Long term storage

Quick-charging should only be done in an emergency; slow

charging is recommended.

9.7. Check of commutator brush and slip ring

Contact your nearest Yanmar dealer.

10. Long-term storage

If storing your engine for long periods, make the following

preparations.

(1) Operate the engine for about 3 minutes and then stop.

(2) Stop the engine. Drain the engine lube oil while the engine is stillwarm and fill with new oil.


Drain Plug

(3) Electric starting:

Turn the engine for 2 ~ 3 seconds with the decomp. lever set atthe non-compression position, and the starter key at the

“START” position. (Do not start the engine.)

(4) Wipe the oil and dirt from the engine and store in a dry place.

- 25 -




11. Unclear points or problems

11. Unclear points or problems

If may instructions are unclear or if problems occur during theoperation of your operator, complete the following form contact your

Yanmar dealer.

(Make a note of your dealer’s name and telephone number on theinside cover of this manual.)

(1) Diesel engine model and serial number, type and number of

generator being used.

Engine model : ……………………………………………

Engine serial number : ……………………………………………

Generator type : ……………………………………………

Generator number : ……………………………………………

(2) Condition

At what stage of operation : …………………………………………

At what rpm : ………………………….

(3) Period of use

Approximately …………… hours

(4) Other details of conditions at the time the problem occurred.

- 26 -




12. TroubleShooting

12. Troubleshooting

12.1. When the engine will not start:

(1) Is there enough fuel?

(2) Is the fuel cock at the “OPEN” position?

(3) Is diesel fuel reaching the fuel injection pump or nozzle?

(4) Is the speed control lever in the “RUN” position?

(5) Is the lube oil level correct?

(6) Is the fuel injection nozzle working properly?

(7) Is the recoil starter pulled sufficiently quickly and firmly?

(8) Is the spark arrester clogged by carbon?

(9) Is the battery discharging?

WARNING:

Keep away from the injection nozzlewhen performing the injection spray test.

Note: Always pull the recoil starter quickly and firmly.(See the section, “How to start your generator.”)

12.2. When no electricity is generated:

(1) Is the main switch turned on?

(2) Are the generator brushes worn?

(3) Are the plugs correctly connected?If electricity is still not generated, take the generator to a Yanmar

dealer.

- 27 -




13. How to connect a cable to a plug rubber 20A

How to connect a cable to the Plug rubber 20A ?

1. Release the rubber insulation from the plug.

2.

Release the shield cover from the plug.3. Connect the cable ( 3 x 2,5 mm) to the plug’s pole which

locate at the front side of the plug, with order :

‘W’ pole for grounding ‘Y’ pole for neutral ‘X’ pole for Phase

(A) (B)

(C) (D)

(E) (F)

(G)

- 28 -




14. Electrical circuit diagram

14. Electrical circuit diagram

- No illustration intended for this section -

- 29 -





Date of purchase

Place of purchase (name of dealer)

Documents

Yanmar Air Cooled,Diesel Generator YDG5001SE