Yanmar Air Cooled,Diesel Generator YDG5001SE
-
Upload
sunthron-somchai -
Category
Documents
-
view
262 -
download
1
Transcript of Yanmar Air Cooled,Diesel Generator YDG5001SE
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 1/37
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.
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 2/37
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
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 3/37
1. Handling your generator
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.
ii
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 4/37
1. Handling your generator
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.
iii
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 5/37
1. Handling your generator
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
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 6/37
1. Handling your generator
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
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 7/37
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
- 1 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 8/37
2. Part names2. Part Names
2. Part names
2.1. Part names
Exhaust outlet Lifting eye
Fuel Filler capControl panel
Door cabinet
- 2 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 9/37
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. Handling your generator
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.
- 3 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 10/37
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
- 4 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 11/37
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 12/37
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
- 6 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 13/37
3. Handling your generator4. Preparation for starting
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.
- 7 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 14/37
3. Handling your generator4. Preparation for starting
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
- 8 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 15/37
3. Handling your generator4. Preparation for starting
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.
- 9 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 16/37
3. Handling your generator4. Preparation for starting
Air cleaner
Wing nut
Air cleaner inspectionport cover
Element
- 10 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 17/37
3. Handling your generator4. Preparation for starting
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
- 11 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 18/37
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
- 12 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 19/37
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.
- 13 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 20/37
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. Operating your generator
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
- 14 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 21/37
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 22/37
6. Operating your generator
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.
- 16 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 23/37
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.
8. Stopping your generator
(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
- 17 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 24/37
7. Load
8. Stopping your generator
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 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 25/37
8. Stopping your generator
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.
9. Periodic checks and maintenance
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 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 26/37
8. Stopping your generator
9. Periodic checks and maintenance
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 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 27/37
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.”)
Oil filler cap / Dipstick
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 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 28/37
8. Stopping your generator9. Periodic checks and maintenance
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 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 29/37
8. Stopping your generator9. Periodic checks and maintenance
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 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 30/37
8. Stopping your generator9. Periodic checks and maintenance
(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 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 31/37
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.
Oil filler cap / Dipstick
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 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 32/37
9. Periodic checks and maintenance
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 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 33/37
9. Periodic checks and maintenance
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 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 34/37
9. Periodic checks and maintenance
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 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 35/37
9. Periodic checks and maintenance
14. Electrical circuit diagram
14. Electrical circuit diagram
- No illustration intended for this section -
- 29 -
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 36/37
8/20/2019 Yanmar Air Cooled,Diesel Generator YDG5001SE
http://slidepdf.com/reader/full/yanmar-air-cooleddiesel-generator-ydg5001se 37/37
Date of purchase
Place of purchase (name of dealer)