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BEFORE YOU OPERATE

YDG Operation Manual

25

34127

Charging the Battery

1. Disconnect the battery cables from the battery.

See Disconnecting and Connecting Battery
Cables on page 25

.

2. Clean terminals on the battery and clamps on

the end of the cables.

3. Connect the positive (+) clamp from the charger

to the positive (+) terminal on the battery.

DANGER

• If the electrolyte is frozen, slowly warm the

battery before you recharge it.

• Avoid serious personal injury or

equipment damage. Before charging,
remove the cap from each cell of the
battery and always make sure there is
plenty of ventilation when charging
battery. Discontinue charging if the
electrolyte temperature exceeds 117 °F (45
°C). While the engine is running or the
battery is charging, hydrogen gas is being
produced and can be easily ignited.
Always keep the area around the battery
well-ventilated and keep sparks, open
flames and any other form of ignition out
of the area.

• Never charge the battery while connected.

The diodes will be damaged by the high
voltage. 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.
Quick-charging should only be done in an
emergency; slow charging is
recommended.

4. Connect the negative (–) clamp from the

charger to the negative (–) terminal on the
battery.

Figure 2

5. When finished charging the battery, unplug the

charger before disconnecting clamps from the
battery.

See Disconnecting and Connecting

Battery Cables on page 25

.

Disconnecting and Connecting
Battery Cables

CAUTION

This generator uses a negative ground 12 VDC
starting system. Always shut down the engine
before removing or attaching battery cables.
Always remove the negative (–) cable first.
Always attach the negative (–) cable last

1. When disconnecting cables, loosen and

disconnect negative (–) cable (1,

from battery.

2. Disconnect positive (+) cable (2,

) from

battery last.

(-)

(+)

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Summary of Contents for YDG Series

Page 1: ...OPERATION MANUAL DIESEL POWERED GENERATORS YDG series YDG3700N 6BYI2 YDG3700V 5BYI2 YDG5500N 6BYI2 YDG5500V 5BYI2 YDG3700N 6EBYI2 YDG3700V 5EBYI2 YDG5500N 6EBYI2 YDG5500V 5EBYI2 en original instructions ...

Page 2: ...o make any change at any time without notice YANMAR is a registered trade mark of YANMAR POWER TECHNOLOGY CO LTD in Japan the United States and or other countries All Rights Reserved No part of this publication may be reproduced or used in any form by any means graph ic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written...

Page 3: ...such disclaimer is prohibited by law If such disclaimer is prohibited by law then implied warranties shall be limited in duration to the life of the express warranty How Long is the Warranty Period The YANMAR standard limited warranty period begins on the date of the delivery of the new YANMAR YDG diesel generator to the first retail purchaser and extends for a period of twenty four 24 months or t...

Page 4: ... order to facilitate any future warranty matters You are responsible for the transportation of the generator to and from the repair location as designated by YANMAR To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor You can locate your nearest authorized YANMAR industrial engine dealer or distributor by visiting the YANMAR CO LTD website at http www yanmar co jp The Japanese la...

Page 5: ...liable for incidental special or consequential damages Such consequential damages may include but not be limited to loss of revenue loan payments cost of rental of substitute equipment insurance coverage storage lodging transportation fuel mileage and telephone costs The limitations in this warranty apply regardless of whether your claims are based on breach of contract tort including negligence a...

Page 6: ...YANMAR to provide the best support for your YANMAR YDG diesel generator At the time of purchase YANMAR highly recommends registering the retail purchaser s information through website http www yanmar co jp as soon as possible If it is not possible to access the website please contact the nearest authorized YANMAR industrial engine dealer or distributor Retail Purchaser Registration ...

Page 7: ...before you operate the machine to ensure that you follow safe operating practices and maintenance procedures Keep this Operation Manual in a convenient place for easy access If this Operation Manual is lost or damaged order a new one from your authorized YANMAR industrial engine dealer or distributor Make sure this manual is transferred to subsequent owners This manual should be considered a perma...

Page 8: ...______________________________________________________ YDG serial No _______________________________________________________________________ Date purchased ______________________________________________________________________ Dealer ______________________________________________________________________________ Dealer phone ________________________________________________________________________ ...

Page 9: ...c Compatibility EMC Directive 2014 30 UE RoHS 2011 65 UE And with the following harmonised standards Machinery EN 12100 UNI EN ISO 8528 1 UNI EN ISO 8528 13 Low Voltage EN 60204 1 Electromagnetic Compatibility EN 55012 2007 EN 61000 6 1 2019 The manufacturer of the machinery take the responsibilty to transmit in response to a motivated request of the National Authorities informations regarding the...

Page 10: ...INTRODUCTION viii YDG Operation Manual This Page Intentionally Left Blank ...

Page 11: ...ng is the Warranty Period i What the Generator Owner must Do ii To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor ii What YANMAR will Do ii What is not Covered by this Warranty iii Warranty Limitations iii Warranty Modifications iii Questions iii Introduction v Record of Ownership vi EC Declaration of Conformity vii Table of Contents ix ...

Page 12: ...Air Cooled Engine 20 Engine Controls Recoil Starter 20 Recoil Starter 20 Decompression Lever 20 Engine Controls Electric Starter 21 Key Switch 21 Engine Speed Control Lever 21 Before You Operate 23 Introduction 23 Battery 24 Checking Battery Electrolyte Level 24 Charging the Battery 25 Disconnecting and Connecting Battery Cables 25 Diesel Fuel 26 Diesel Fuel Specifications 26 Filling the Fuel Tank...

Page 13: ...g Periodic Maintenance 44 The Importance of Daily Checks 44 Keep a Log of Generator Hours and Daily Checks 44 YANMAR Replacement Parts 44 Tools Required 44 Ask Your Authorized YANMAR Industrial Engine Dealer or Distributor for Help 44 Tightening Fasteners 45 Tightening Torques for Standard Bolts and Nuts 46 Periodic Maintenance Schedule 47 Periodic Maintenance Procedures 49 Dismantling 60 Troubles...

Page 14: ...TABLE OF CONTENTS xii YDG Operation Manual This Page Intentionally Left Blank ...

Page 15: ...to it make sure you order the new part and decal at the same time DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a situation whi...

Page 16: ...or outside and far away from windows doors and vents DANGER Explosion Hazard Always place the diesel fuel container on the ground when transferring the diesel fuel from the pump to the container Hold the hose nozzle firmly against the side of the container while filling it This prevents static electricity buildup which could cause sparks and ignite fuel vapors Diesel fuel is flammable and explosiv...

Page 17: ...therefore the generating set MUST NOT be connected to an earthling system Cables length must be under 200 m in order to properly ensure safety for the end user The appliances connected to the sockets of the gen set unless double insulated ones class II must be equipped with PE conductor in order to ensure equipotential bonding between the conductive structural parts of gen set and the appliances I...

Page 18: ... is being produced and can be easily ignited Keep the area around the battery well ventilated and keep sparks open flame and any other form of ignition out of the area Avoid serious personal injury or equipment damage Always turn off the battery switch if equipped or disconnect the negative battery cable before servicing the equipment Fire Hazard Avoid personal injury or equipment damage Have appr...

Page 19: ...ation the generator must be switched off the cables must be disconnected and the tank must be empty When you need to transport a generator set for repair have a helper assist you when attaching it to a hoist and loading it on a truck WARNING Electrical Hazard Make welding repairs safely Always turn off the battery switch if equipped or disconnect the negative battery cable and the leads to the alt...

Page 20: ...e area Always remove anything that creates slippery areas around the generator Avoid personal injury Always stop the engine before beginning service WARNING Burn Hazard Avoid serious injury Some of the generator set surfaces become very hot during operation and shortly after shut down Always keep hands and other body parts away from hot generator set surfaces Always handle hot components with heat...

Page 21: ...cation of load when the engine is started could be very dangerous NOTICE Never attempt to modify the generator set design or safety features such as defeating the engine speed limit control or the diesel fuel injection quantity control Modifications may impair the generator set s safety and performance characteristics and shorten the generator set s life Any alterations to this generator set may a...

Page 22: ...wered items Never attach tools or appliances to the generator before it is started Always disconnect tools and appliances from the generator before starting NOTICE Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear The standard range of ambient temperatures for the normal operation of YANMAR engines is from 5 F 15 C to 113 F 35 C...

Page 23: ... receptacle Always protect the air cleaner and electric components from damage when you use steam or high pressure water to clean the generator Always turn battery switch OFF if equipped or disconnect the negative battery cable before servicing the electrical system Never operate the generator set while wearing a headset to listen to music or radio because it will be difficult to hear warning sign...

Page 24: ... related instructions Operation with the machine when it is not working in perfect conditions either functionally or in terms of safety Operation without following the inspection maintenance schedule Any unauthorized modification of or removal of safety equipment Use of spare parts and accessories that are unsuitable or have not been approved by Yanmar Operation in flammable or hazardous environme...

Page 25: ...series single cylinder air cooled diesel engine for applications such as YANMAR YDG generators YANMAR s series of LV engines use one of the most advanced single cylinder technologies available Yanmar YDG generators are designed to supply power to a wide variety of applications including Construction Agriculture Household We are sure that you will agree these features provide excellent value in an ...

Page 26: ... 7 Fuel tank 8 Fuel filler cap 9 Starter switch only for electric version 10 Compression release lever 11 Fuel injection pump 12 Air cleaner 13 Generator set model and serial number decal 14 Engine control lever 15 Recoil starter 16 Oil filler cap dipstick 17 Oil drain plug 18 Oil filter 19 Oil pressure switch 20 Generator unit 21 Generator engine damper mounts 22 Battery only for electric version...

Page 27: ...Fuel filler cap 9 Starter switch only for electric version 10 Compression release lever 11 Fuel injection pump 12 Air cleaner 13 Generator set model and serial number decal 14 Engine control lever 15 Recoil starter 16 Oil filler cap dipstick 17 Oil drain plug 18 Oil filter 19 Oil pressure switch 20 Generator unit 21 Generator engine damper mounts 22 Battery only for electric version Figure 2 06346...

Page 28: ...OMPRESSION LEVER DOWN 3 PULL THE STARTER ROPE HARD AND FAST ALL THE WAY OUT ELECTRIC WARM UP ENGINE FOR ABOUT 5 MINUTES H L C A U T I O N D I E S E L F U E L F L A M M A B L E E N G I N E M U S T B E T U R N E D O F F W H E N A D D I N G F U E L D O N O T O P E R A T E T H E E N G I N E I N D O O R S O R I N P O O R L Y V E N T I L A T E D P L A C E S S L O W P O S I T I O N N O L O A D O N L Y RE...

Page 29: ...N L Y READ OPERATION MANUAL FOR COMPLETE INSTRUCTIONS CHECK THE ENG INE OIL CC CLASS SAE 10W30 OIL CHANGE EYE RY 100hr DO NOT OPERATE THE ENGINE IN STAND WATER OR RAIN OPERATION C H E C K F U E L A N D E N G I N E O I L L E V E L B E F O R E S T A R T I N G O P E N T H E F U E L C O C K M O V E T H E E N G I N E S P E E D L E V E L T O T H E R U N P O S I T I O N Ź72 6723 1 1 RECOIL RETURN ENGINE ...

Page 30: ...ed on the left side of the generator body Figure 5 Engine Nameplate Typical The engine nameplate Figure 7 is located on the cooling shroud on the PTO side of engine above the starter 1 Figure 6 Figure 6 Figure 7 View Z Z 1 MADE IN ITALY l MODEL MAX OUTPUT DISPLACEMENT ENGINE NO min 1 kW ...

Page 31: ...filters Inlet and outlet fuel filters are provided to remove contaminants and sediment from the diesel fuel Periodic cleaning replacement is required See Periodic Maintenance Schedule on page 47 Fuel tank The fuel tank is a reservoir that holds diesel fuel Fuel is gravity fed to the fuel injection pump Since fuel is used to keep fuel system components cool and lubricated more fuel than is necessar...

Page 32: ...YDG3700N 6BYI2 YDG5500N 6BYI2 1 Voltage meter 2 AC circuit breaker Generator main switch circuit breaker 3 DC circuit breaker 12 VDC output 4 12 VDC output receptacle For 12 VDC battery charging only 5 Grounding terminal 6 Schuko socket 230V 7 CEE socket 230V Figure 8 240 200 0 0 V 1 2 6 4 5 3 7 ...

Page 33: ...0N 6EBYI2 1 Voltage meter 2 AC circuit breaker Generator main switch circuit breaker 3 Engine start key switch 4 DC circuit breaker 12 VDC output 5 12 VDC output receptacle For 12 VDC battery charging only 6 Grounding terminal 7 Schuko socket 230V 8 CEE socket 230V Figure 9 240 200 0 0 V 1 2 6 4 5 3 7 8 ...

Page 34: ...able with the recoil starter Recoil Starter A recoil starter allows you to manually start an engine by pulling on the recoil starter handle 1 Figure 10 When you pull on the handle you set the flywheel and crankshaft in motion The recoil starter is spring loaded so the handle and attached rope automatically return to the recoil starter assembly Decompression Lever Pressing the decompression lever 2...

Page 35: ...the key to this position to start the engine As soon as the engine starts release the key and it will automatically return to the ON position NOTICE Never hold the key in the START position for longer than 15 seconds or the starter motor will overheat Engine Speed Control Lever NOTICE If using the stop lever to shut down the engine be sure to return the key switch to the OFF position to prevent di...

Page 36: ...PRODUCT OVERVIEW 22 YDG Operation Manual This Page Intentionally Left Blank ...

Page 37: ...l describes activating a new battery diesel fuel and engine oil specifications and how to replenish them It also describes the proper way to connect the electrical loads to the generator and the daily engine checkout Before performing any storage procedures within this section review the Safety section on page 1 ...

Page 38: ...c acid Never allow battery fluid to come in contact with clothing skin or eyes Severe burns could result Always wear safety goggles and protective clothing when servicing the battery If battery fluid contacts the eyes and or skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment If the engine cranking speed is so slow that the engine does no...

Page 39: ...er charge the battery while connected The diodes will be damaged by the high voltage 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 Quick charging should only b...

Page 40: ... diesel fuel Additional technical fuel requirements The fuel cetane number should be equal to 45 or higher The sulfur content must not exceed 0 5 by volume Less than 0 05 is preferred Bio diesel fuels See Bio diesel fuels on page 27 Never mix kerosene used engine oil or residual fuels with the diesel fuel Water and sediment in the fuel should not exceed 0 05 by volume Keep the fuel tank and fuel h...

Page 41: ...diesel fuels must comply with the American Standard ASTM D 6751 and ASTM D 7467 for Oxidation stability 2 Bio fuels should be purchased only from recognized and authorized diesel fuel suppliers In North America bio diesel and bio diesel blends must be purchased from the BQ 9000 accredited producers and BQ 9000 certified distributors Precautions and concerns regarding the use of bio fuels 1 Free me...

Page 42: ...when engine oil is low Engine Oil Specifications NOTICE Never mix different types of engine oil This may adversely affect the lubricating properties of the engine oil Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize and or shorten engine life Use an engine oil that meets or exceeds the following guidelines and classification...

Page 43: ... from contaminating the engine oil Always clean the oil cap dipstick and the surrounding area before you remove the cap 3 Reinsert oil cap dipstick into crankcase and turn clockwise for one half revolution to engage the first thread in the crankcase opening 4 Remove oil cap dipstick The oil level should be between upper 2 Figure 7 and lower 3 Figure 7 lines on the oil cap dipstick NOTICE Always ke...

Page 44: ...repair person Also if the generator is powering electrical circuits the chance of an electrical fire exists 1 Only use grounded extension cords Be sure to use an extension cord with the proper wire gauge size See the following table 2 If electrical separation cannot be adopted for indirect contact protection see page 3 properly ground the unit Attach a 10 stranded copper ground wire to the ground ...

Page 45: ... the main AC switch of the generator 1 Figure 9 or 1 Figure 10 and any other loads Make sure nothing is plugged into or connected to the generator CAUTION Do not start two or more appliances simultaneously and always start them one at a time Never use floodlights with other appliances Connection with utilities must be done only with sockets located on generator control panel 1 Figure 9 shows the m...

Page 46: ...st all lights and small appliances in the other For standby service to home or building only include items you must power CAUTION Do not start two or more appliances simultaneously and always start them one at a time Never use floodlights with other appliances 2 Enter running watts of each item except electric motors The light bulb or appliance nameplate lists its wattage Remember 1 kW 1000 watts ...

Page 47: ...000 Furnace fan 1 3 hp blower motor 600 1800 Vacuum cleaner 600 750 Sump pump 1 3 hp 700 2100 Refrigerator freezer 800 2400 Deep freezer 500 1500 Circular saw 1000 2500 2300 4600 Circular saw 6 in 800 1000 Floodlight 1000 1000 Drill 1 2 in electric 1000 1250 Toaster 1200 1200 Coffee maker 1200 1200 Skillet 1200 1200 Chain saw 14 in electric 1200 1500 Water well pump 1 2 hp 1000 3000 Hot plate rang...

Page 48: ...and helps extend the life of the engine Visual checks Check battery electrolyte level Check diesel fuel and engine oil levels Visual Checks CAUTION If any problem is noted during the visual check the necessary corrective action should be taken before you operate the generator set 1 Check for engine oil leaks 2 Check for fuel leaks WARNING Always wear eye protection when servicing the generator set...

Page 49: ...DUCTION This section of the Operation Manual describes the procedures for starting the generator checking generator performance during operation and shutting the generator down Before performing any storage procedures within this section review the Safety section on page 1 ...

Page 50: ...g is plugged into or connected to the generator See Generator Check on page 30 4 Turn the key clockwise from the OFF position 1 Figure 23 to the ON position 2 Figure 23 Figure 23 5 Move the engine control lever 1 Figure 24 to the RUN position 2 Figure 24 Figure 24 6 Grasp the recoil starter handle 1 Figure 25 7 Pull the handle out slowly until you feel strong resistance 8 Slowly return the recoil ...

Page 51: ...ep 5 Electric Start Use the following procedure to start the engine using the electric starter 1 Make sure you follow the procedures stated in Daily Checks on page 34 2 Fill fuel tank with clean fresh fuel See Filling the Fuel Tank on page 28 3 Before starting always turn OFF the main AC switch of the generator and any other loads Make sure nothing is plugged into or connected to the generator See...

Page 52: ... have the necessary repairs performed Contact your authorized YANMAR industrial engine dealer or distributor 3 Check for white or black smoke from the exhaust system A small amount of white exhaust smoke is normal on start up of a cold engine Black exhaust smoke could mean the engine is overloaded or is being over fueled If either of these conditions persists contact your authorized YANMAR industr...

Page 53: ...ed from the engine To avoid this run the engine at 3 4 load or greater for 30 minutes or longer every 50 hours operation SHUTTING DOWN THE GENERATOR NOTICE For maximum engine life YANMAR recommends that when shutting the engine down you allow the engine to run without load for five minutes This will allow the engine components that operate at high temperatures such as the exhaust system to cool sl...

Page 54: ...ppliances are in good working order before connecting them to the generator If an appliance begins to operate abnormally becomes sluggish or stops suddenly turn off the generator main AC switch immediately Then disconnect the appliance and examine it for malfunction Due to high mechanical stresses only tough rubber sheathed flexible cables are permitted When using extension lines or mobile distrib...

Page 55: ...harged before charging WARNING Never allow the free ends of the cables to touch each other If this occurs the battery will short circuit 2 Start the generator set 3 Connect the charging cable to the battery terminals and to the DC output terminals of the generator NOTICE Always connect the positive battery terminal to the positive DC terminal on the generator Never reverse the charging cables or s...

Page 56: ...GENERATOR OPERATION 42 YDG Operation Manual This Page Intentionally Left Blank ...

Page 57: ... PERIODIC MAINTENANCE INTRODUCTION This section of the Operation Manual describes the procedures for proper care and maintenance of the generator set Before performing any storage procedures within this section review the Safety section on page 1 ...

Page 58: ...s assume that the daily checks are performed on a regular basis Make it a habit of performing daily checks before the start of each shift See Daily Checks on page 34 CAUTION It is important to perform daily checks Periodic maintenance prevents unexpected downtime reduces the number of accidents due to poor engine performance and helps extend the life of the engine Keep a Log of Generator Hours and...

Page 59: ... starting any maintenance procedure disconnect negative battery cable Attach a Do Not Operate tag near the key switch while performing maintenance procedure on the equipment Tightening Fasteners Use the correct amount of torque when you tighten fasteners on the machine Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure ...

Page 60: ...xagon bolt 7T and nut M6 1 0 mm 7 9 lb ft 87 104 lb in 9 8 11 8 N m 1 0 1 2 kgf m Use 80 of the value at left when the tightening part is aluminum Use 60 of the value at left for 4T bolts and locknuts M8 1 25 mm 17 21 lb ft 200 251 lb in 22 6 28 4 N m 2 3 2 9 kgf m M10 1 5 mm 33 40 lb ft 44 1 53 9 N m 4 5 5 5 kgf m M12 1 75 mm 58 72 lb ft 78 4 98 0 N m 8 0 10 kgf m M14 1 5 mm 94 108 lb ft 127 5 14...

Page 61: ...0 hours Every 1000 hours Every 1500 hours Every 2000 hours Air intake Clean or replace air cleaner element may need more frequent service in dusty conditions Cylinder head Adjust intake exhaust valve clearance Check compression Electrical equipment Check battery if equipped and add water as necessary Before operation Check battery indicator if equipped and other driven machine indicators if equipp...

Page 62: ...place fuel system hose s or every 2 years whicheve r comes first Generator Check brushes for wear or damage Check slip rings for wear or damage Check coils and Automatic Voltage Regulator AVR for correct operation Frame Check main and sub frames for damage Check engine frame dampers for wear damage and tightness Check all fasteners for damage and tightness Check Replace Contact your authorized YAN...

Page 63: ...el See Checking Battery Electrolyte Level on page 24 Check battery indicator Visually check the battery indicator if equipped and any other indicator provided by the driven machine manufacturer Check engine oil level Before you operate the engine check the engine oil level See Checking Engine Oil on page 29 Check for engine oil leakage Before you operate the engine check for any engine oil leaks I...

Page 64: ... your authorized YANMAR dealer or distributor repair the damage Check for engine oil leakage Check for fuel leakage Check for engine oil leakage After you shut down the engine check for any engine oil leaks WARNING Avoid being burned by contact with hot engine oil Check for fuel leakage After you shut down the engine check for any fuel leaks DANGER Avoid personal injury Always wear eye protection ...

Page 65: ...er under the engine to collect waste oil 5 Remove one of the drain plugs located on the bottom of the cylinder block 2 Figure 32 Allow oil to drain WARNING The engine oil will be hot after engine operation stay clear of the hot engine oil to avoid being burned Always wear eye protection Figure 32 6 Remove the oil cap dipstick 1 Figure 32 to allow the engine oil to drain more easily NOTICE Prevent ...

Page 66: ...il cap dipstick 1 Figure 33 See Adding Engine Oil on page 30 NOTICE Never overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage Figure 33 11 Warm up the engine by running it for five minutes and check for any engine oil leaks 12 After engine is warm shut it off and let it sit for 10 minutes 13 Recheck the engine oil level by reinserting the oil cap dipstick int...

Page 67: ... to the engine as specified in Adding Engine Oil on page 30 NOTICE Never overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 9 Warm up the engine by running it for five minutes and check for any engine oil leaks 10 After engine is warm shut it off and let it sit for 10 minutes 11 Recheck the engine oil level by reinserting the oil cap dipstick into the crankc...

Page 68: ...tion Clean air cleaner element Replace engine oil and clean inspect engine oil filter Check engine speed control Drain the fuel tank and replace outlet fuel filter Clean air cleaner element Engine performance is adversely affected when the air cleaner element is clogged with dust Be sure to clean or replace the air cleaner element periodically Avoid operating in extremely dusty conditions When the...

Page 69: ...ent replace the air filter element 7 If either element is damaged replace both of them They are not sold individually 8 Clean the inside of the air cleaner cover 2 Figure 36 Figure 36 9 Reinstall the air cleaner element 4 Figure 36 into the air cleaner housing 10 Slide the outer foam element 5 Figure 36 over the air cleaner element 4 Figure 36 11 Reinstall the wing nut 3 Figure 36 and hand tighten...

Page 70: ...tributor for service 1 Speed control lever 2 RUN position 3 Stop lever Figure 37 Drain the fuel tank and replace outlet fuel filter 1 Position an approved container under the fuel tank to collect the fuel DANGER Always wipe up all spills immediately Diesel fuel is flammable and explosive under certain conditions Store any containers containing fuel in a well ventilated area away from any combustib...

Page 71: ...r adjustment is necessary to maintain the correct timing for opening and closing the valves Improper adjustment will cause the engine to run noisily resulting in poor engine performance and engine damage See your authorized YANMAR industrial engine dealer or distributor for this service Check brushes for wear or damage Check the generator brushes for wear and damage Generator brushes wear with nor...

Page 72: ...e properly installed and tightened to the specified value given in the YDG Service Manual See your authorized YANMAR industrial engine dealer or distributor for service and replacement parts Perform the following maintenance every 1000 hours of operation Check compression Check engine frame dampers for wear damage and tightness Check compression An engine compression check is required every 1000 h...

Page 73: ... dealer or distributor for this service Perform the following maintenance every 2000 hours of operation Check and replace fuel hoses Check and replace fuel hoses Regularly check the fuel system hoses If they are cracked or degraded replace them Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubb...

Page 74: ...l PERIODIC MAINTENANCE PROCEDURES Dismantling The user is in charge of all the operations that must be done when the generator s life is over and must follows laws and local regulation Dismantling operations must be done by qualified technicians ...

Page 75: ... serial number information label is located inside the top front frame rail See Generator Set Decal on page 15 2 Model name and serial number of your engine The engine nameplate is located on the cooling shroud on the PTO side of engine above the starter See Engine Nameplate Typical on page 16 3 How long the generator has been in service the number of generator hours or the number of calendar mont...

Page 76: ...stops Key switch not in the ON position Turn key to the ON position Starter motor does not operate or rotates too slowly engine can be turned manually Battery needs charging Check electrolyte recharge Faulty cable connection at battery terminals Clean terminals retighten Disconnecting and Connecting Battery Cables on page 25 Faulty starter switch See authorized YANMAR industrial engine dealer or d...

Page 77: ...NMAR industrial engine dealer or distributor AVR fuse interrupted Faulty AVR Winding failure Insulation failure Wrong or incorrectly carried out connections Too low or too high no load voltage Faulty AVR Winding failure Faulty slip ring Too low load voltage Faulty AVR See authorized YANMAR industrial engine dealer or distributor Possible overload Check load current value Too high load voltage Faul...

Page 78: ...OLTAGE TRIMMER AC COIL ROTOR COIL AUX COIL 4P DC TERMINALS DC BREAKER STOP SOLENOID OIL PRESSURE SWITCH RELAY AC BREAKER AC 230 V CEE SOCKET EARTH TERMINAL BL BL RE RE RE RE BU BU GE GE BL BR BU RE BR BU YE GR AC 230 V SCHUKO SOCKET VOLTMETER ALTERNATOR BR BU BL BL YE GR YE GR AC COIL AC COIL BL Black RE Red BU Blue BR Brown GE Grey YE GR Yellow Green ...

Page 79: ...OLENOID OIL PRESSURE SWITCH RELAY AC BREAKER AC 230 V CEE SOCKET EARTH TERMINAL OFF I II KEY SWITCH OPERATION DIAGRAM GR WH GR WH GR WH GR WH GR WH GR RE YE BL RE BL BL BL RE RE RE RE BU BU BL BL GE GE BL BR BU RE BR BU YE GR AC 230 V SCHUKO SOCKET VOLTMETER BAT IG ST B E ALTERNATOR BR BU BL BL YE GR BL BR BU YE GR E B IG BAT ST OFF I II BL Black RE Red YE Yellow GR Green BU Blue BR Brown GE Grey ...

Page 80: ...TS CONNECTIONS under Electrical Separation condition x2 CLASS II EQUIPMENT NO GROUNDING x1 CLASS I EQUIPMENT NO GROUNDING x1 CLASS I EQUIPMENT x1 CLASS II EQUIPMENT NO GROUNDING x2 CLASS I EQUIPMENT NOT PERMISSIBLE INSULATING MATERIAL I E WOOD RUBBER ETC THE GENSET MUST BE PLACED ON A NON CONDUCTIVE SURFACE SEE ASIDE FIGURE ...

Page 81: ...TROUBLESHOOTING YDG Operation Manual 67 341 27 HJHQG 66 48 30 17 66 48 30 17 57 187 57 52 1 L1 L1 N N PE PE 5 1 5 0 25 5 127 1 8 1 6 23 2 6833 75 48 30 176 211 7 216 71 V VWHP ZLWK 5 ...

Page 82: ...TROUBLESHOOTING 68 YDG Operation Manual This Page Intentionally Left Blank ...

Page 83: ... Qr gtcv k qp Ocpwcn LONG TERM STORAGE INTRODUCTION This section of the Operation Manual describes the procedures necessary to place the generator into long term storage three months or longer and how to prepare it for operation ...

Page 84: ...ir cleaner muffler and electrical components dynamo starter motor switches from water and dust 8 Disconnect the negative battery cable to prevent the battery from discharging 9 Check the battery fluid and add distilled water as required See Check Battery Electrolyte Level on page 34 10 Charge the battery once a month during storage See Charging the Battery on page 25 11 Clean the generator and sto...

Page 85: ...t 14 2 A 21 7 A Power factor 1 0 Phase Single phase No of poles 2 Type of insulation H class Bearing system Ball bearing grease enclosed Output terminal AC AC240 V 16 A DC Terminal Black Red Breaker AC 14 A NFB 22 A NFB DC 12 A thermal breaker Voltmeter AC300 V Emergency stop system Engine stop device by low level oil sensor Generator unit Dimension L 650 mm 720 mm W 496 mm 480 mm H 530 mm 578 mm ...

Page 86: ... 0 Phase Single phase No of poles 2 Type of insulation H class Bearing system Ball bearing grease enclosed Output terminal AC AC230 V 16 A DC Terminal Black Red Breaker AC 13 A NFB 20 A NFB DC 12 A thermal breaker Voltmeter AC300 V Emergency stop system Engine stop device by low level oil sensor Generator unit Dimension L 650 mm 720 mm W 496 mm 480 mm H 530 mm 578 mm Protection IP23M Performance C...

Page 87: ...ection timing bTDC by FIC 20 20 Valve clearance 0 15 0 05 mm PTO position Crankshaft Direction of rotation Counterclockwise viewed from PTO side Fuel injection pump Fuel injection nozzle Valve opening pressure 200 kgf cm2 Fuel selection See Diesel Fuel on page 26 Fuel filter 5 µm Governor All speed type mechanical Balancer shaft Single shaft Engine weight dry with electric start 41 0 kg 53 5 kg wi...

Page 88: ...40 C With cooling fan air cleaner muffler YANMAR standard After engine break in period Output allowable deviation 3 1 PS 0 7355 kW 1 hp SAE Society of Automotive Engineers 0 7457 kW Starting system Electric start recoil start Dimensions L 354 mm 367 mm W 436 mm 459 mm H 453 mm 492 mm Oil capacity Upper limit 1 05 L 1 6 L Lower limit 0 65 L 1 0 L Fuel tank capacity 13 0 L Battery capacity 35 Ah Eng...

Page 89: ...ion timing bTDC by FIC 13 5 13 0 Valve clearance 0 15 0 05 mm PTO position Crankshaft Direction of rotation Counterclockwise viewed from PTO side Fuel injection pump Fuel injection nozzle Valve opening pressure 200 kgf cm2 Fuel selection See Diesel Fuel on page 26 Fuel filter 5 µm Governor All speed type mechanical Balancer shaft Single shaft Engine weight dry with electric start 41 0 kg 53 5 kg w...

Page 90: ...7355 kW 1 hp SAE Society of Automotive Engineers 0 7457 kW Starting system Electric start recoil start Dimensions L 354 mm 367 mm W 436 mm 459 mm H 453 mm 492 mm Oil capacity Upper limit 1 05 L 1 6 L Lower limit 0 65 L 1 0 L Fuel tank capacity 13 0 L Battery capacity 35 Ah Engine model L70V5 G E YDG2 L100V5 G E YDG2 Generator YDG3700V 5 E B YDG5500V 5 E B 0 250 500 750 1000 1250 1500 1750 2000 25 ...

Page 91: ...70 877 9894 FAX 1 770 877 9009 https www yanmar com us Yanmar Engine Shanghai Corporation Ltd 1101 1106 Gopher Center Building No 757 Meng Zi Road Shanghai China P R C 200023 http www yanmar china com cn TEL 86 21 2312 0688 FAX 86 21 6880 8682 Yanmar Asia Singapore Corporation Pte Ltd 4 Tuas Lane Singapore 638613 TEL 65 6861 3855 FAX 65 6862 5189 https www yanmar com sg Yanmar Europe B V Brugplein...

Page 92: ...YIYDG EN0000 2021 10 YANMAR ITALY S p A http www yanmaritaly it ...

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