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YANMAR
YANMAR AIR COOLED
DIESEL GENERATOR
YDG5001SE
3. PREVENTING BURNS
4. BRAKING
Provide stoppers for the wheels so that the generator will not move
during operation.
ii
iii
7.
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
2. Part names
1. Specification
1. Specifications
Model
Item
Type
Frequency
Hz
50
60
220
4.2
4.2
230
5.0
5.0
Voltage (AC)
KVA
Kw
V
Current (AC)
19.1
Rated output
Engine
YDG5001SE
Revolving field type single-phase alternating current generator
Revolution speed
18.3
3000
rpm
Power factor
120/240
41.7/20.8
45.5/22.7
3600
Single phase
Number of poles
Excitation
Self-excitation type
Insulation
Type E
Ball bearing
Type
Model
Continous
Output rated output
Maximum
Power
output
Kw/rpm
(Hp/rpm)
Kw/rpm
(Hp/rpm)
mm (in)
86 x 70 (3.38 x 2.76)
Displacement
Cooling system
Lubrication system
Lube oil capacity
Starting system
Fuel oil
cc (in3)
406 (24.8)
Forced air-cooled system
Forced lubrication
1.65 (1.74)
Electric
Diesel fuel
110/220
1.0
Phase
Generator
110/220
38.2/191
Grease-enclosed
4-cycle single cylinder air cooled diesel engine
L100AE-DEGYS 5
L100AE-DEGYS 6
5.7/3000
6.6/3600
(7.7/3000)
(9.0/3600)
6.5/3000
7.3/3600
(10.0/3600)
(8.8/3000)
l (US qts)
l (US qts)
YDG5001SE: 16 (4.22)
-1-
2. Part names
2. Part Names
2.
Part names
Lifting eye
Control panel
Door cabinet
-2-
AC supply lamp
Voltage meter
Key switch
AC output
-3-
Air cleaner
check port cover
-4-
may shorten the life of the engine. Follow the break-in procedures
during the first 20 hours.
(1) Avoid overloads
Avoid applying any heavy loads during the break-in period.
(2) Change engine oil regularly
Change the engine oil at first 50 hours or at the end of
first month, and every 3 months or 200 hours thereafter.
Note:
Be sure to drain the oil while the engine is warm. Later, it may be
difficult to drain the oil completely.
Start Up
First time
Approx. one month of 50 hours.
Thereafter
Every 3 months or 200 hours
-5-
CAUTION:
Only use the recommended diesel fuel oil. Use of nonrecommended fuel may cause clogging in the fuel oil
strainer, fuel injection pump, and fuel injection nozzle.
This clogging often causes sudden engine stops after
starting.
Fuel should have a cetane value of more than 45 in order to
prevent difficult starting, misfiring, and white exhaust smoke.
Diesel fuel oil substitutes are not recommended; they may
be harmful to the fuel system components.
Fuel should be free of water or dust because these cause
trouble in the fuel injection pump and nozzle.
(3) Do not overfill
Overfilling is dangerous. Do not fill the tank beyond
the top of the red plug inside the fuel tank filter.
Fuel tank
capacity
(l )
Upper level
/Lower level
YDG5001SE
16 / 0.5
-6-
WARNING:
Refuel in a well-ventilated area with the engine stopped.
Do not smoke or allow flames or sparks in the area where
the engine is refueled or where gasoline is stored.
Do not overfill the tank. Make sure the filler cap is securely
closed after refueling.
Be careful not to spill fuel when refueling. If any fuel is
spilled, 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 insufficient
lube 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 its
combustion.
CAUTION:
The YDG-SE series is equipped with a Low Oil Warning
System/Stop Device (Option for YDG-E models). This safety
device stops the engine during operation when the oil
pressure falls lower than the limit, or the lube oil level
becomes too low. This prevents accidents such as bearing
seizures, etc.
Use the appropriate lube oil in order to preserve your
generator.
Nothing affects the performance and durability of your
generator more than the lube oil you use. If inferior oil is
used, or if your engine oil is not changed regularly, the risk
of piston seizure, piston ring sticking and accelerated wear of
the cylinder liner, bearing and other moving components
increases significantly.
-7-
5W
Service
Grade
5W30
10W
10W30
20W
20W40
20
30
40
-30
-20
-10
10
20
30
40
Fill the oil up to the filler port with the engine placed on the level.
Lube Oil
YDG5001SE
capacity
(l )
Upper level 1.65 / 1.05
/Lower level
-8-
Drain Plug
CAUTION:
When checking the oil level, make sure your generator is
sifting on the level. If it is tilted, you may add either too
much or too little oil. If you overfill, your engine will consume
too much oil. If you do not add enough oil, the oil
temperature will rise dangerously high, and the oil will
rapidly degenerate. Engine seizures may also result.
So, be sure to check the oil with the engine on a level
surface and the engine stopped.
To check the oil, simply dip the dipstick into the oil pan. Do
not screw in the dipstick.
The YDG-SE models are equipped with an low oil warning
System/Stop Device, but be sure to check the oil level and to
refill with oil to the specified level before starting the
generator.
4.3 Servicing your air cleaner
(1)
-9-
Air cleaner
Wing nut
Element
- 10 -
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)
Turn off
the switch
downward
- 11 -
WARNING:
The generator should be earthed to prevent electric shocks.
NOTE:
5.
WARNING:
Do not hook up toots or other apparatus to the generator
before it has been started.
5.1. Electric starting
The engine is started in the manner described below.
(1) Starting
1). Open the Fuel Cock
- 12 -
Direction
to Open
- 13 -
Caution:
If the starting motor is turned for too long, the battery will
go 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 Alarm
Lamp is not lit.
CAUTION:
Low Oil Warning System Generators
The blinking of the lube oil alarm lamp is activated by low oil
pressure or a lube oil shortage. The engine stops
automatically. The engine will stop immediately if restarted
without a lube oil refill. Check the oil level and refill.
Engine speed
limiting bolt
Fuel injection
limiting bolt
- 14 -
Load
(50Hz/60Hz)
Type
Single-phase
Generator
CAUTION:
Do not start 2 or more machines simultaneously. Start them
one by one.
Do not use floodlights together with other machines.
7.1. AC application
(1) Start the engine and make sure the pilot lamp comes on. If it
does not, the filament may be burnt out.
(2) Plug in the appliance.
CAUTION:
Be sure that all appliances are in good working order before
- 15 -
7.2. DC application
The DC receptacle may be used for charging 12 volt automotive-type
batteries only. (Other loads may not be used.)
Applicable battery:
9 When AC output receptacle is used: 18 - 35 AH (20 hrs.
rating)
9 When AC output receptacle is not used: 18-60 AH (20
hrs. rating)
(1) When using automotive-type batteries with battery cables, be
sure to disconnect the minus (-) battery cable from the battery
before charging.
(2) Start the engine
(3) Connect the charging cable to the battery terminals and the DC
terminals of the generator.
CAUTION:
Connect the positive battery terminal to the positive
generator terminal. Do not reverse the charging cables, or
serious 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 -
7. Load
8. Stopping your generator
WARNING:
Batteries produce explosive gases. Keep sparks, flames, and
cigarettes well away. To prevent the possibility of creating a
spark near the battery, always connect the charging cables
to the battery first and only then to the generator. When
disconnecting, you should disconnect the cables at the
generator first.
CAUTION:
Do not attempt to start an automobile engine while the
generator is still connected to the battery. The generator
may 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 -
7. Load
8. Stopping your generator
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 -
Close
position
(5) Slowly pull out the recoil handle until pressure is felt (that is, to
the point in the compression stroke where the intake and
exhaust 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 the
generator in good condition and maintenance durability. The chart
below indicates which checks to make and when to make them. The
mark ( ) indicates that special tools and skills are required. Consult
your Yanmar dealer.
WARNING:
Shut off the engine before performing any maintenance. If
the engine must be run, make sure the area is well
ventilated. The exhaust contains poisonous carbon monoxide
gas.
- 19 -
Maintenance schedule
Part
Item
Check the fuel level
and refill if necessary
Daily check
Every year
or every
1000hrs
Before
Operation
Once
a month
Every month
Every 3
Every 6
or every
month or
month or
50hrs
every 200hrs every 400hrs
After
Operation
Air
induction
System
Electric
System
Engine
Body
Generator
Before
Operation
1st time
1st time
2nd time
& thereafter
2nd time
& thereafter
After
Operation
Before
Operation
- 20 -
Drain Plug
- 21 -
Oil filter
Every 6 months or
400 hours
(or earlier if dirty)
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 defective
element.
Note:
A clogged element hinders the flow of air to the combustion
chamber. This reduces engine output, increases lube oil and
fuel 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 maximum
engine output.
Clean
Replace
Every 3 months or
200 hours
Every 6 months or
400 hours
Fuel tank
(1) Drain the fuel oil from the fuel tank by releasing the fuel intake
hoses.
- 23 -
(2) Loosen the small screws of the fuel cock and pull out the filter
from 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 and
exhaust valves.
This requires special tools and skills, so contact your Yanmar
dealer.
WARNING:
Do not perform the injection nozzle test near an open fire or
any other kind of fire, The fuel spray may ignite. Do not bare
skin to the fuel spray. The fuel may penetrate the skin and
cause injury to the body. Always keep your body away from
the 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 of
ventilation.
Discontinue charging if the electrolyte temperature exceeds
45C (117 F).
CAUTION:
Do not charge the battery with the battery cable still
connected. The high voltage will damage the diodes.
Connect the (+) lead of the charger to the (+) terminal of
the battery, and the () lead to the () terminal. Reversed
polarity will damage the charger rectifier or the battery.
After charging is completed, connect the battery cables
correctly to the battery. Reversed polarity wiring will damage
the diodes.
- 24 -
Drain Plug
- 25 -
Generator type
Generator number
(2) Condition
At what stage of operation
At what rpm
: .
- 26 -
12. Troubleshooting
12.1. When the engine will not start:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
WARNING:
Keep away from the injection nozzle
when 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)
(2)
(3)
Are the plugs correctly connected?
If electricity is still not generated, take the generator to a Yanmar
dealer.
- 27 -
(A)
(B)
(C)
(D)
(E)
(F)
(G)
- 28 -
- 29 -
Date of purchase
Place of purchase (name of dealer)