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Manual Genset MOBIS-TBI PDF
Manual Genset MOBIS-TBI PDF
YANMAR
YANMAR AIR COOLED
DIESEL GENERATOR
YDG5001SE
This Operation Manual tells you how to operate and service your new
Yanmar generator. Please read it before using the generator to
insure proper handling and operation. Follow the instructions
carefully to keep your engine in the best running condition. If you
have any question concerning this manual, please contact your
nearest Yanmar dealer. This Operation Manual deals with the main
points for operation of the YDG generator.
WARNING:
Indicates a strong possibility of severe personal injury or loss of life if
instructions are not followed.
A CAUTION:
Indicates a possibility of personal injury or equipment damage if
instructions are not followed.
Note:
Gives helpful information.
WARNING:
The Yanmar generator is designed to give safe and dependable
service provided that it is operated according to instructions.
Read and understand the Operation Manual before operating the
generator. Failure to do so could result in personal injury or
equipment damage.
i
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 not
spill fuel. Wipe away all fuel spills with a clean cloth. Keep gasoline,
kerosene, matches and other explosives and inflammables away from
the generator, because the temperature around the exhaust muffler
is very high during operation.
To prevent fire hazards and to provide adequate ventilation,
keep the generator at least 3 ft (1 ml away from buildings
and other equipment during operation.
Operate the generator on a level surface. There may be fuel
spillage if the generator is tilted.
Do not put the generator indoors while the engine is still hot.
3. PREVENTING BURNS
4. BRAKING
Provide stoppers for the wheels so that the generator will not move
during operation.
ii
1. Handling your generator
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. This
could cause damage to the generator and to electrical
appliances in the house.
iii
1. Handling your generator
iv
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
2. Part names
1. Specification
1. Specifications
Model YDG5001SE
Item
Type Revolving field type single-phase alternating current generator
Frequency Hz 50 60
KVA 4.2 5.0
Rated output
Kw 4.2 5.0
Voltage (AC) V 220 230 110/220 120/240 110/220
Current (AC) A 19.1 18.3 38.2/191 41.7/20.8 45.5/22.7
Engine
-1-
2. Part names
2. Part Names
2. Part names
Exhaust outlet
Lifting eye
Door cabinet
-2-
2. Part Names Part names
3. Handling your generator
Key switch
-3-
2. Part Names Part names
3. Handling your generator
Air cleaner
check port cover
-4-
3. Handling your generator
4. Preparation for starting
may shorten the life of the engine. Follow the break-in procedures
during the first 20 hours.
-5-
3. Handling your generator
4. Preparation for starting
CAUTION:
Only use the recommended diesel fuel oil. Use of non-
recommended 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.
Fuel tank
YDG5001SE
capacity
(l )
Upper level 16 / 0.5
/Lower level
-6-
3. Handling your generator
4. 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 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.
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.
-7-
3. Handling your generator
4. Preparation for starting
S.A.E
5W
Service
5W30
Grade
10W
10W30
20W
20W40
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-
3. Handling your generator
4. Preparation for starting
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.
-9-
3. Handling your generator
4. Preparation for starting
Air cleaner
Wing nut
Element
- 10 -
3. Handling your generator
4. 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 the
wing nut.
Turn off the main switch and any other loads (such as the light and
motor switches).
WARNING:
Be sure to turn off the main switch before starting, because
connected tools or appliances may become a hazard.
Turn off
the switch
downward
- 11 -
4. Preparation for starting
5. 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.
WARNING:
Do not hook up toots or other apparatus to the generator
before it has been started.
(1) Starting
1). Open the Fuel Cock
- 12 -
4. Preparation for starting
5. How to start your generator
Direction
to Open
- 13 -
5. How to start your generator
6. Operating your generator
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.
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 -
6. Operating your generator
7. Load
(3) What about the color of the exhaust gas? (Is it black or too
white?)
If you notice any of the above, stop the engine and contact your
nearest Yanmar dealer.
WARNING:
If the engine has been running, the muffler will be very hot.
Be careful not touch the muffler.
Never refill the fuel tank while the engine is running.
7. Load
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 -
6. Operating your generator
7. Load
NOTE:
If overloading of the circuit trips the AC circuit protector,
reduce ti-re electrical load on the circuit, and Wait a few
minutes before resuming operation.
7.2. DC application
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)
(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.
- 17 -
7. Load
8. Stopping your generator
CAUTION:
Do not stop the engine suddenly because this may cause the
temperature 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 is
placed at the STOP position, either turn the fuel oil cock to
CLOSE position (SE type only) or loosen the nut of high
pressure fuel pipe on the pump side to stop the engine.
In such case, contact your nearest Yanmar to locate the
cause 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. Stopping your generator
9. Periodic checks and maintenance
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.
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 -
8. Stopping your generator
9. Periodic checks and maintenance
Maintenance schedule
Every month Every 3 Every 6 Every year
Part Item Daily check or every month or month or or every
50hrs every 200hrs every 400hrs 1000hrs
Check the fuel level Before
and refill if necessary Operation
Once
Drain the fuel tank
a month
Clean the fuel tank
Fuel Oil System
2nd time
Replace the lube. Oil
1st time & thereafter
2nd time
Clean lube. Oil filter
1st time & thereafter
After
Check for lube. Oil leakage
Operation
Air
Check the air cleaner element
induction
System
Replace the air cleaner element
Electric Check the battery liquid level Before
System and refill if necessary Operation
Engine Adjusting the intake and exhaust
Body valve clearance
Check commutator brush
Generator
and slip ring
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 the
engine.
- 20 -
8. Stopping your generator
9. Periodic checks and maintenance
Remove the oil filler cap. Remove the tam plug and drain the old oil
while tie engine is still warm. The plug is located on the bottom of
the cylinder Sock. Tighten the drain plug and refill with the
recommended oil, (See the section under Preparations for starting.)
Drain Plug
Loosen the fixing bolt and then pull out the oil filter.
- 21 -
8. Stopping your generator
9. Periodic checks and maintenance
Oil filter
Do not wash the air cleaner element with detergent because this is a
oil-soaked type element.
Every 6 months or
Change 400 hours
(or earlier if dirty)
Element
See the section for changing the air cleaner element under
Preparations for starting.
- 22 -
8. Stopping your generator
9. Periodic checks and maintenance
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.
Every 3 months or
Clean
200 hours
Every 6 months or
Replace
400 hours
Fuel tank
(1) Drain the fuel oil from the fuel tank by releasing the fuel intake
hoses.
- 23 -
8. Stopping your generator
9. Periodic checks and maintenance
(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.
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.
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 -
9. Periodic checks and maintenance
10. Long term storage
(1) Operate the engine for about 3 minutes and then stop.
(2) Stop the engine. Drain the engine lube oil while the engine is still
warm and fill with new oil.
Drain Plug
(4) Wipe the oil and dirt from the engine and store in a dry place.
- 25 -
9. Periodic checks and maintenance
11. Unclear points or problems
(1) Diesel engine model and serial number, type and number of
generator being used.
Engine model :
Generator type :
Generator number :
(2) Condition
At what rpm : .
Approximately hours
- 26 -
9. Periodic checks and maintenance
12. TroubleShooting
12. Troubleshooting
12.1. When the engine will not start:
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.)
- 27 -
9. Periodic checks and maintenance
13. How to connect a cable to a plug rubber 20A
(A) (B)
(C) (D)
(E) (F)
(G)
- 28 -
9. Periodic checks and maintenance
14. Electrical circuit diagram
- 29 -
Date of purchase