Model VD5000
Contents
1. 16 DLOPDING MNE SENAT SG 18 Periodic 2 19 Storage and Maintenant avse 21 Troubleshooting Repair 22 10 MIN DE EM sa 23 Failure to properly follow these precautions result property damage serious injury or DEATH Read all labels and the owner s manual before operating this generator Operate only in well ventilated areas Exhaust gas contains carbon monoxide a poisonous colorless odorless gas and can be deadly Always stop the engine before refueling Wait 5 minutes before restarting Check for spilled fuel or leaks Clean and or repair before use Keep any source of combustion away from fuel tank at all times Do not operate near flammable materials or in an explosive atmosphere Do not operate this unit in wet conditions or with wet hands Use of a generator in rain snow or near water can result in electrocution Keep the generator dry at all times The VD5000 comes with a weather resistant not not weatherproof enclosure Connections for standby power to a building s electrical system must be made by a qualified electrician and must comply with all applicable laws and electrical codes Improper connections can allow electrical current from the generator to back feed into the utility lines Such back feed may electrocute utility compan2. Daily First 20 100 hours or 500 hours or 1000 hours ltem Hours three months six months or every PoE Check Battery and cables 1 E Check Fuel Level Check Oil Level Replace engine oil Check Air Filter O Element Replace air cleaner Clean oil filter replace if necessary Clean fuel filter Replace Fuel Filter Check fuel injection pump Check fuel injector Check fuel lines replace if Po necessary Adjust valve clearance Check carbon brush and slip rings service more frequently in dirty or dusty conditions Note indicates special tools and or knowledge required Contact an authorized Voltmaster service center as necessary 19 7 1 Changing the engine oil Remove the oil filler cap Remove the drain plug and 1 drain the old while the engine is still warm The plug Tele is located the bottom of the cylinder block Tighten T 1 the drain plug and refill with the recommended oil 7 2 Clean the engine oil filter 7 3 Replace the air cleaner element Do not clean the air cleaner element with detergent 7 4 Clean and replace fuel filter The fuel oil filter also has to be cleaned regularly to insure maximum engine output 1 Drain out the fuel from the fuel tank Remove the small screw of the fuel cock and pull out the filter from the filler port 3 Wash the
3. and the life of the generator is shortened The recommendation is for an API classification of CH 4 CG 4 or CF 4 The rating may be in combination with SJ SH or SG for example CH 4 SJ Choose the applicable viscosity oil according to local ambient temperature SAE Grades J 10 82 30 10 AMBIENT TEMPERATURE 11 To connect the battery first connect the positive red cable to the positive post of the battery Use the fasteners provided and ensure the connection is secure Next connect the negative black cable securely to the negative battery terminal Use the reverse order when disconnecting the battery Air cleaner 1 Unscrew the wing nut remove the air cleaner cover and take out the element Wing nut Do not wash the element with detergent Replace the element when dirty or the paper is torn Never run the generating set without the element or rapid engine wear will result 2 Reattach the air cleaner cover and tighten the wing securely 12 1 Turn all circuit breakers and disconnect any loads he generator should be grounded to prevent electric shocks The first 20 hours are considered a break in period for the engine Please observe the following instructions Warm up the engine 5 minutes upon the initial start Run the engine with no load until the engine becomes warm Avoid applying any heavy loads during the break in period No more than
4. filter thoroughly with diesel fuel Loosen the fastening nut bottom cover and delivery discs for cleaning any deposits 7 5 Check the injection nozzle and fuel injection pump Consult the service manual 7 6 Check the generating set carbon brush and slip ring Consult the service manual 20 8 STORAGE AND EXERCISE 8 1 Short Term Storage 1 Add oil to the maximum level without overfilling 2 Fill tank with fresh diesel fuel Treat with a quality diesel fuel conditioner 3 Exercise the generator every 30 days Run it with at least a 50 load 2500 watts for 30 minutes This will serve to lubricate the injection pump and bake out any moisture that has accumulated in the generator windings 8 2 Long Term Storage If storing the generator for periods exceeding 30 days perform the following steps 1 Operate the engine for about 3 minutes and then stop 2 Drain the engine oil while the engine is warm and fill with fresh oil 3 Remove the screw plug on the cylinder head cover and add 2cc of clean engine oil then replace the plug 4 MRecoil starting Push the decompression lever down Non compression position and hold it while you pull the recoil starter 2 3 times Do not start the engine Electric starting Turn the engine 2 3 seconds with the decompression lever set at the non compression position and the starting key at the START position Do not start the engine 5 Wipe off any oil and dirt fro
5. ground fault circuit interrupter shuts off power to the protected receptacles if a ground fault or current imbalance between two conductors is detected If the reset button pops out the appliance connected to the receptacle may be defective If the appliance appears to be in good condition press the reset button until a Click is heard This will restore power If the reset button pops out again disconnect all appliances disconnected immediately and have them inspected by a qualified electrician before attempting to use them again 17 1 Disconnect loads 2 Turn off all circuit breakers 3 Run the generating set without load for 3 minutes Do not stop the engine suddenly or the temperature will increase abnormally Press down on the stop lever Turn the key to OFF Place the fuel cock lever to S position f the engine keeps on running after the speed lever is placed in the STOP Withtiengine speed lever atSTOPpositieh Stop lever position turn the fuel cock to the CLOSE position m Do not stop the engine with the decompression lever m Do not stop the generating set with load applied Stop it after the load removed 18 7 PERIODIC MAINTENANCE Periodic maintenance is very important to keep the generator in optimum running condition The chart below indicates what checks and adjustments are necessary and at what interval Interval
6. 50 load 2500 watts is recommended Replace the engine oil while the engine is warm after the initial 20 hour run time 13 Do not plug any tools or appliances into the generator before starting procedures 1 Open the fuel cock 2 Set the engine speed lever at the RUN position 3 Pull out the recoil starter handle Pull out the handle until you feel the resistance then return it back to the initial position Press down the decompression lever It will return automatically when the recoil starter is pulled Firmly pull the recoil starter handle Do not allow the handle grip to snap back against the engine Return it gently to prevent damage to the starter mechanism When the engine is difficult to start in cold weather remove the screw plug from the cylinder head cover and add 2cc engine oil Be sure to replace the plug to prevent moisture and dirt from entering the engine The use of aerosol starting fluids is prohibited Severe piston damage may result 14 1 Starting The preparations for electric starting the same as for the recoil starting Open the fuel cock Set the engine speed lever at the RUN position m Turn the starting key clockwise to START position Remove your hand from the key as soon as the engine starts If the starting motor does not start after 10 seconds wait 15 seconds before starting it again 15 Warm up the engine wit
7. D gt O Rated voltage AC Rated current AC 37 5 18 8 Rated speed rpm 3600 Phase single phase Power factor 1 0 Excitation mode self excitation constant voltage AVR Structure mode Open Frame Gross weight Ibs kg 286 6 130 28 4x18 9x33 3 Dimensions LxWxH in mm 720x480x845 Model KM186FB Type Vertical 4 stroke single cylinder air cooled direct injection diesel engine Continuous output kW rpm 6 3 Max Power kW rpm 6 6 Bore x stroke in mm 3 39x2 95 86x75 Displacement cu in cc 17 17 436 Cooling system Forced air cooled system Valve Clearance Intake Exhaust 15 mm Lubricating system Pressure splash combined type Lube oil capacity qt L 1 45 1 65 Starting system recoil electric Fuel Diesel Fuel capacity gal L 3 96 15 Low oil pressure alarm included Fuel tank Air cleaner Starting handle Recoil starter Engine speed lever Oil drain plug filler cap Dipstick Muffler Fuel filler cap Low Pressure Warning Light Voltmeter 0 300V Circuit Breakers 120V 20A GFCI Receptacle Hourmeter 120V 30A Receptacle Grounding Stud Voltage Selection Switch 120 240V 20A Receptacle The generator serial number identifies your particular unit and is important when ordering parts and accessories A serial number bar code sticke
8. Diagram SA Power on amp Power off Relation Table 120V 120V7 240V XK 1F1 CT Breaker Breaker Current Transformer xT Connecting Terminal 53 120 240 52 fo 5 120 T Volt Breaker Electrical Starter FU Rectifier FR EE es HE ie 1 1523 j 1 LASER 8 AN Warring Generator 1 EE Low Ol Alert Module EE 4 Starting Motor 5 Charging Winding Oil Pressure Switch 23 Voltmaster is Wanco brand Voltmaster Wanco and the Voltmaster Wanco logos are registered trademarks of Wanco Inc All other trademarks are property of their respective owners WANCO INC 5870 Tennyson Street Arvada Colorado 80003 800 730 3927 303 427 5700 303 427 5725 guww voltmaster com 2015 Wanco Inc All rights reserved
9. Model VD5000 Diesel Generator a a 5 S User s Manual January 2015 VOLIT MASTE This manual covers the operation and preventive maintenance of the VD5000 diesel generator This manual is primarily concerned with the generator specifications function troubleshooting and repair All information in this publication is based on the latest product information available at the time of approval for printing No part of this publication may be reproduced without written permission If a problem should arise or if you have any questions about the generator consult an authorized Voltmaster service center Our generators are designed to give safe and dependable service if 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 Several preventive maintenance procedures require background knowledge in diesel engines Be sure to consult an authorized service center when necessary A service manual and parts breakdown are available at www voltmaster com Safety Information and Specifications GOMPONMENt IGSNUTCATION 5 Preparation SENG 10 SENDE NE GENET NLP 14 Operating the GeneratOl massar
10. between the generator set ground terminal on the control panel and an external ground source Do not hook up tools or other appliances to the generator before it has been started If equipment is plugged and the circuit breakers are on the generator starting motion may cause sudden movements of the equipment and possibly result in injuries Be sure to disconnect any tool or appliance from the generator prior to starting Most motors require more than their rated current for start up Do not exceed the specified current limit of any receptacle Do not connect the generator set to household circuit without an approved transfer switch This could cause damage to the generating set and to electrical appliances the house Your generator is equipped with a wet acid style battery Leakage of battery electrolyte is possible if the case is penetrated or the battery is upended Battery electrolyte contains sulfuric acid Protect your eyes skin and clothing In case of contact flush thoroughly with water and get prompt medical attention Batteries generate hydrogen gas which can be highly explosive Do not smoke or allow flames or sparks near a battery at any time Charge the battery only in a well ventilated area MAIN TECHNICAL SPECIFICATIONS AND DATA Item Model VD5000 Rated frequency Hz om Max power KVA Rated power kVA 4 5 NO I N
11. fueling careful not to spill fuel when refueling If any fuel is spilled make sure the area is dry before starting the engine Always check the engine oil level with the generator on a level surface before starting and refill if necessary The engine may be damaged if operated with insufficient engine oil it is also dangerous to overfill the oil level 10 VD5000 generator is equipped with a low oil pressure warning and shutdown system This system stops the engine automatically when the oil pressure falls below a safe level and prevents catastrophic engine failure Do not operate the generator with this system disabled Check the oil level Take out the oil filler cap and clean the indicator stick with a clean lint free rag Reinsert the oil filler cap without rotating it Remove the oil filler cap and examine the oil level If the oil level is at or below the lower level refill the oil to the upper limit mark Reinsert the oil filler cap and tighten securely The oil capacity of the engine is 1 45 qt 1 65 L Engine Oil Selection It is very important to select the proper engine oil to maintain good performance and life of the generator If an inferior engine oil or oil of the wrong grade is used or if your engine oil is not replaced periodically the risk of piston seizure piston ring sticking and accelerated wear of the cylinder liner bearings and other moving parts increases significantly
12. hout load for three minutes 1 Abnormal sound or vibration 2 Engine misfiring or rough running 3 Heavy exhaust smoke especially blue or black If you notice any of the above mentioned conditions stop the engine and correct the problems before running the generator 1 After switching on the circuit beakers observe the voltmeter on the control panel or digital display Do not operate the generator if a reading other than 120 5 volts is observed 2 Connect the equipment to the generating set in order i e the appliances with the highest current load first mif overloading of the circuit trips an AC circuit breaker reduce the electrical load on the circuit and wait a few minutes before resuming operation 3 The generator is designed to permit simultaneous 120 and 240 volt operation 16 The voltage selection switch has two positions AC120V 120 240 1 When the voltage selection switch is in the 120 240V position the generator supplies both 120V and 240V AC power If you operate the generator with the switch in this position the electric current is limited to 15 amps to the 120V receptacles although it can provide 15 amps at 240V from the 120 240V receptacle 2 When the voltage selection switch in the 120V position the generator supplies 120V AC only It can supply a full 30 amps to the 30 Amp receptacle or 20A to the receptacle Total current is limited to 33 amps at rated load The GFCI
13. m the engine and store in a dry place 21 9 TROUBLESHOOTING 9 1 The diesel engine will not start or is difficult to start Fault Deteriorated diesel fuel in the tank Drain the tank and refuel with fresh diesel fuel Remedy Fuel filter is clogged Clean or replace fuel filter Fuel Cock is not in the Start position The governor lever of the engine Turn it to the START position Switch to the start position throttle is not in the start position Oil filter is clogged causing low oil Clean or replace oil filter pressure switch to activate Low oil pressure switch failure Check wiring and replace switch as necessary Air in the fuel lines often occurs Consult the service manual for bleeding procedure after running out of fuel Valves out of adjustment Check valve adjustment and reset as necessary refer to service manual Insufficient battery voltage Check battery state and terminals and cables energize starter and or fuel solenoid Engine governor spring is defective Replace governor spring Valves out of adjustment Check valve adjustment and reset as necessary refer to service manual Governor out of adjustment Adjust governor refer to service manual 9 3 No AC output Fault Remedy Circuit Breakers closed _ Open circuit breakers Receptacle is defective Check wiring and check or replace receptacle 22 10 Wiring
14. r is placed on the generator and on the shipping carton Additionally it is engraved onto a metal serial number tag riveted to the generator Selection of diesel fuel Your diesel engine is designed to run on ultra low sulfur diesel fuel ATSM 2 D is the most suitable for the engine at temperatures above 32 F 0 C 1 D is recommended for temperatures below 32 F 0 C Cetane rating of at least 45 is recommended for reliable starting Winter fuels are often blended by refineries so for optimum performance don t use stored winter fuel in warmer weather Keep dust and water out of the fuel When filling the fuel tank from drums make sure that no dust or water is mixed in the fuel Serious fuel injection pump and injector problems will result Do not overfill Overfilling is very dangerous Do not fill the tank beyond the top of the red plug inside the fuel strainer Below 15 degrees F wax crystals begin to form in diesel fuel These will clog the fuel filter and stop the engine as the temperature drops toward 0 F Any good winter fuel conditioner for diesel fuel will keep the fuel moving to at least 20 degrees Follow the manufacturer s instructions 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 the fuel oil stored Do not overfill the tank make sure the filler cap is securely closed after re
15. y workers or others who contact the lines during a power outage and when utility power is being restored the generator may explode burn or cause fires in the building s electrical system Never add fuel to the fuel tank while the engine is running Wipe off any overflow of diesel fuel with a clean cloth Keep explosives and other flammable products away from the generator set prevent fire and to provide adequate ventilation keep the generator at least three feet one meter away from buildings and other equipment during operation Operate the generator a level surface Do not put the generator indoors while the engine is hot Exhaust gas contains poisonous carbon monoxide which is harmful to your health and possibly fatal Never use the generating set in confined spaces or poorly ventilated areas The muffler and the engine body are very hot while the engine is running and remains so for a time after the generator has been shut off Do not touch these parts to prevent possible severe burns To avoid electric shocks or short circuits do not touch the generating set when your hands are wet The generator is not waterproof so it should not be used in a place exposed to rain snow or water spray Use of the generator in a wet location can cause short circuits and electrical shocks during operation The generator should be grounded to prevent electrical shocks from faulty loads Connect a length of heavy wire
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