YANMAR YDG Series Diesel-Powered Generators User Manual

YANMAR YDG Series Diesel-Powered Generators

Product Information

The YDG series is a range of diesel-powered generators manufactured by YANMAR POWER TECHNOLOGY CO., LTD. The specific models in the series are YDG3700N- 6BYI2, YDG3700V-5BYI2, YDG5500N-6BYI2, YDG5500V-5BYI2, YDG3700N-6EBYI2, YDG3700V-5EBYI2, YDG5500N-6EBYI2, and YDG5500V-5EBYI2.

This product is covered by a limited warranty provided by YANMAR. The warranty covers defects in material and/or workmanship for the duration of the warranty period.

It is important to note that this warranty is provided in lieu of all other warranties, except where prohibited by law. YANMAR disclaims any implied warranties of merchantability or fitness for a particular purpose.

Product Usage Instructions

1. Transportation: As the owner, you are responsible for transporting the generator to and from the repair location designated by YANMAR.
2. Finding Authorized Dealers or Distributors: To locate an authorized YANMAR industrial engine dealer or distributor, visit the YANMAR CO., LTD. website at www.yanmar.co.jp. Click on the Global icon for English language support.
3. Repairs and Replacements: If any part(s) of the YANMAR generator covered by the warranty are found to be defective, YANMAR will make repairs and/or replacements at no cost to you for parts or labor. The repairs and/or replacements will be made at a location designated by YANMAR.

Please note that this warranty does not cover any modifications made to the warranty terms unless they are in writing and signed by both parties. This warranty agreement is the complete and exclusive agreement between you and YANMAR regarding warranties.

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

Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and/or specifications to explain and/or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. YANMAR is a registered trademark 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 – graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems – without the written permission of YANMAR POWER TECHNOLOGY CO., LTD.
In case of exporting this product and providing the related technical material to non-residents in Japan or residents in overseas, it is required to comply with the export and trade control laws and regulations of Japan and other relevant countries. Please be careful to proceed with necessary procedure.

OPERATION MANUAL

MODEL

YDG3700V-5EBYI2, YDG3700V-5BYI2, YDG5500V-5EBYI2, YDG5500V-5BYI2 YDG3700N- 6EBYI2, YDG3700N-6BYI2, YDG5500N-6EBYI2, YDG5500N-6 BYI2

CODE

YIYDG-EN0000

All Rights Reserved, Copyright YANMAR ITALY S.p.A.

YANMAR YDG Operation Manual WARRANTIES
YANMAR LIMITED WARRANTY
What is Covered by this Warranty?
YANMAR warrants to the original retail purchaser that a new YANMAR YDG diesel generator will be free from defects in material and/or workmanship for the duration of the warranty period.
This warranty is provided in lieu of all other warranties, express or implied. YANMAR specifically disclaims any implied warranties of merchantability or fitness for a particular purpose, except where 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 two-thousand (2000) engine operation hours, whichever occurs first. The warranty period (by duration or operation hours) begins on the date of delivery to the original retail purchaser and is valid only until the applicable warranted duration has passed or the operation hours are exceeded, whichever comes first.

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YANMAR WARRANTIES
YANMAR limited warranty – continued
What the Generator Owner must Do:
If you believe your YANMAR generator has experienced a failure due to a defect in material and/or workmanship, you must contact an authorized YANMAR industrial engine dealer or distributor within thirty (30) days of discovering the failure. You must provide proof of ownership of the generator, proof of the date of the generator purchase and delivery, and documentation of the generator operation hours. Acceptable forms of proof of delivery date include, but are not limited to: the original warranty registration or sales receipts or other documents maintained in the ordinary course of business by YANMAR dealers and/or distributors, indicating the date of delivery of the YANMAR product to the original retail purchaser. This information is necessary to establish whether the YANMAR product is still within the warranty period. Thus, YANMAR strongly recommends you register your generator as soon as possible after purchase in 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 language page will be displayed.) For English language “click” on “Global” icon.
· “Click” on “Dealer Locator” in the website heading to view the “Dealer Locator” menu.
· Choose the Country from the pull down menu.
· Choose the Product Category from the pull down menu.
· “Click” on “Search” to browse YANMAR dealer or distributor.
· You may also contact YANMAR by clicking on “Contact” icon in the website heading and typing in your question or comment.
What YANMAR will Do:
YANMAR warrants to the original retail purchaser of a new YANMAR generator that YANMAR will make such repairs and/or replacements at YANMAR’s option, of any part(s) of the YANMAR product covered by this warranty found to be defective in material and/or workmanship. Such repairs and/or replacements will be made at a location designated by YANMAR at no cost to the purchaser for parts or labor.

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YANMAR limited warranty – continued

YANMAR WARRANTIES

What is not Covered by this Warranty?
This warranty does not cover parts affected by or damaged by any reason other than defective materials or workmanship including, but not limited to, accident, misuse, abuse, “Acts of God,” neglect, improper installation, improper maintenance, improper storage, the use of unsuitable attachments or parts, the use of contaminated fuels, the use of fuels, oils, lubricants, or fluids other than those recommended in your YANMAR Operation Manual, unauthorized alterations or modifications, ordinary wear and tear, and rust or corrosion. This warranty does not cover the cost of parts and/or labor required to perform normal/scheduled maintenance on your YANMAR generator. This warranty does not cover consumable parts such as, but not limited to filters, fuel injector nozzle, lubricants and cleaning fluids. This warranty does not cover the cost of shipping the product to or from the warranty repair facility.

Warranty Limitations:
The foregoing is YANMAR’s only obligation to you and your exclusive remedy for breach of warranty. Failure to follow the requirements for submitting a claim under this warranty may result in a waiver of all claims for damages and other relief. In no event shall YANMAR or any authorized industrial engine dealer or distributor be 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 and strict liability) or any other theory. Any action arising hereunder must be brought within one (1) year after the cause of action accrues or it shall be barred. Some states and countries do not allow certain limitations on warranties or for breach of warranties. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state and country to country. Limitations set forth in this paragraph shall not apply to the extent that they are prohibited by law.

Warranty Modifications:
Except as modified in writing and signed by the parties, this warranty is and shall remain the complete and exclusive agreement between the parties with respect to warranties, superseding all prior agreements, written and oral, and all other communications between the parties relating to warranties. No person or entity is authorized to give any other warranty or to assume any other obligation on behalf of YANMAR, either orally or in writing.

Questions:
If you have any questions or concerns regarding this warranty, please call or write to the nearest authorized YANMAR industrial engine dealer or distributor or other authorized facility.

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YANMAR WARRANTIES
YANMAR limited warranty – continued
Retail Purchaser Registration
It is very important for the original retail purchaser to register the YANMAR product. Registration enables 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.

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INTRODUCTION

Welcome to the world of YANMAR!
YANMAR has been the leader in industrial diesel engines for over 90 years. We developed the world’s first practical small-sized diesel engine in 1933. Our engineers are continuously developing new technology to keep YANMAR on the leading-edge of the industry. The diesel-powered generator is only one example of the new technology we have developed. We are committed to maintaining our environment, and are proud of our history of innovation, quality and respect for operator safety.
To help you enjoy your YANMAR diesel generator (YDG) for many years to come, please follow these recommendations:
· Read and understand this Operation Manual 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 permanent part of the generator and remain with it.

· Constant efforts are made to improve the quality and performance of YANMAR products, so some details included in this Operation Manual may differ slightly from your generator. If you have any questions about these differences, please contact your authorized YANMAR industrial engine dealer or distributor.
· When exporting or providing this product and manual to non-residents, please comply with the security trade control laws and regulations of Japan and other relevant countries.

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INTRODUCTION
RECORD OF OWNERSHIP
Take a few moments to record the information you need when you contact YANMAR for service, parts or literature. YDG model:__ YDG serial No.:___ Date purchased:__ Dealer:__ Dealer phone:____

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INTRODUCTION
34127
EC DECLARATION OF CONFORMITY
According with Machinery Directive 2006/42/CE, Annex II.1.A

Manufacturer: Address:

YANMAR ITALY s.p.a.
Via Camperio, 9 – 20123 Milano (MI)

We DECLARE hereby, under our sole responsibility

That the machine named: YANMAR DIESEL GENERATOR

Model:

Serial Number:

Year of construction:

IS IN CONFORMITY

With the provisions of the following European Directives:

–

Machinery Directive 2006/42/CE

–

Low Voltage Directive 2014/35/UE

–

Electromagnetic 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 machinery related to this declaration.

Name and address of the pearson authorized to compile and keep the technical documentation :

Pearson empowered to draw up the declaration

__Ing._Ca_rl_o_C_a_v_a_l_le_r_o____ President (—————-)

____I_ng. _C_a_r_lo_C__a_v_a_lle_r_o____ President (—————-)

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INTRODUCTION This Page Intentionally Left Blank

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TABLE OF CONTENTS This Page Intentionally Left Blank

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SAFETY

YANMAR considers safety of great importance and recommends that anyone that comes into close contact with its products, such as those that install, operate, maintain or service YANMAR products, exercise care, common sense and comply with the safety information in this manual and on the machine’s safety decals. Keep the decals from becoming dirty or torn and replace them if they are lost or damaged. Also, if you need to replace a part that has a decal attached to it, make sure you order the new part and decal at the same time.
This safety alert symbol appears with most safety statements. It means attention, become alert, your safety is involved! Please read and abide by the message that follows the safety alert symbol.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which can cause damage to the machine, personal property and/or the environment or cause the equipment to operate improperly.

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.

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SAFETY

SAFETY PRECAUTIONS
There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance.
DANGER
Be assured no children or animals are in the surrounding zone of generator set during operation and handling.
DANGER
· Never permit anyone to install or operate the generator set without proper training.
· Read and understand this Operation Manual before you operate or service the generator set to ensure that you follow safe operating practices and maintenance procedures.
· Safety signs and decals are additional reminders for safe operating and maintenance techniques.
· See your authorized YANMAR dealer or distributor for additional training.
Exhaust Hazard
·Never operate the generator in an enclosed area. Operating a generator indoors can kill you in minutes. Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. Only operate the generator 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 explosive under certain conditions. Always store any containers containing fuel in a well-ventilated area, away from any combustibles or sources of ignition. Wipe up all spills immediately and never use a shop rag to catch spilled fuel.
· Before you operate the engine, check for fuel leaks.
· Avoid serious personal injury. Never jump-start the engine. Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion. Only use the key switch to start the engine.
· Avoid serious personal injury or equipment damage. 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 place diesel fuel, flammable material such as oil, hay or dried grass or chemical gases or fumes close to the engine during engine operation or shortly after shut down.
· Never use metal pipe that carries combustible materials or gases to ground the generator.
· Never operate the generator in explosion risk ambients

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DANGER
Electric Shock Hazard
· Always have a licensed electrician connect the generator to the utility circuit. The generator must not be connected to other power sources.Improper installation can cause the generator to back-feed into the utility power line. This may electrocute a power company line repair person.
· Never use if the generator is wet or damp.
· Never use the generator in a location exposed to rain, snow, water spray or standing water. If the generator must be used outside, protect it from the weather. Moisture or ice can cause a malfunction or short circuit in the electrical components which could result in electrocution.
· Never operate the generator in rain or a floodplain unless proper precautions are taken to avoid being subject to rain or a flood.
· Never use any worn or damaged electrical cords. Electric shock or damage to the generator may result.
· Never touch the generator with wet hands or when the generator is wet.
· Never use the generator in highly conductive areas. These areas include metal decking and steelwork.
· Never handle live terminals or bare wires.
· Protection against indirect contact with live circuit parts is assured by ELECTRICAL SEPARATION. The exposed conductive parts and conductive structural parts need to be equipotential bonded. The coils of the alternator of the generating sets are not bonded to the frame of the machine, 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

SAFETY
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.
· If using electrical separation protection method for indirect contact, the GENSET must be physically disconnected from the ground (refer to page 66 scheme).
· It is therefore IMPORTANT that you ONLY use the generator to supply equipment in the following combinations.
· One or more of “CLASS II“ equipment
· Only ONE item of “CLASS I“ equipment
· One or more of “CLASS II“ equipment and only ONE item of “CLASS I“ equipment.
· At page 66 are shown different cases of load connections. All not mentioned connection schemes are NOT allowed.
· Protection by means of ELECTRICAL SEPARATION is not suitable for complex circuits or for those ones placed in dangerous environments that could easily lead to an electric shock. In these cases, the end user must comply with local safety standards and laws. I.E. It is possible to install an RCD (30 mA) and bond neutral to the frame of the gen-set (refer to page 67). This operation must be carried out by qualified electricians only. Now the connection to an earthling system become mandatory (see page 30), in order to ensure protection against indirect contacts with live circuits by means of RCD, use the earth terminal placed on the control panel of the gen-set and a high efficiency cable.

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SAFETY

DANGER
Fire Hazard
· Never use metal pipe that carries combustible materials or gases to ground the generator.
· Do not put the generator indoors while the engine is still hot.
· Never jump-start the engine. Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion.
· Never operate the generator if powered items overheat, electrical output drops, there is sparking, flames or smoke coming from the generator or if the receptacles are damaged.
· Never operate the generator closer than 3.3 ft (1 m) away from buildings and other equipment or sources of combustion during operation.
Falling Hazard
Avoid injury or equipment damage due to the generator set falling. Always secure the generator set to prevent the generator set from falling during maintenance.

WARNING
Explosion Hazard
· Avoid serious personal injury or equipment damage. While the engine is running or the battery is charging, hydrogen gas 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 appropriate safety equipment available.
· Keep fire extinguishers handy in case of fire. Clearly indicate the location of the fire extinguishers with a safety sign.
· Ensure that the type of fire extinguishers are appropriate for material that might catch fire. Check with local authorities.
· Have all fire extinguishers checked periodically for proper operation and/or readiness.
· Post evacuation routes prominently. Periodically conduct fire drills.
Avoid personal injury. Always read and follow safety-related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers.

Always wipe up all spills immediately.
The user must comply with safety regulation applicable in the place where the genset has been sold.

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WARNING
Entanglement Hazard
· Rotating parts can cause severe injury or death. Never wear jewelry, unbuttoned cuffs, ties or loose fitting clothing and always tie long hair back when working near moving/rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts.
· Avoid personal injury. Never leave the key in the key switch when servicing the generator set. Someone may accidentally start the engine and not realize you are servicing it. Attach a “Do Not Operate” tag near the key switch while performing maintenance on the equipment.
Severe Hazard
· Avoid personal injury. Rotating parts can cause severe injury or death.
·Never operate the generator without the guards in place.
Lifting Hazard
· Avoid serious personal injury. Additional equipment is necessary to lift the generator set. Always use lifting equipment with sufficient capacity to lift the generator.
· 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.
· During transportation, 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.

SAFETY
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 alternator when welding on the equipment.
· Connect the weld clamp to the component to be welded and as close as possible to the welding point.
· Never connect the weld clamp to the generator set or in a manner which would allow current to pass through a mounting bracket.
· When welding is completed, reconnect the leads to the engine charging system prior to reconnecting the battery.
Shock Hazard
· Check the electrical harnesses for cracks, abrasions and damaged or corroded connectors. Always keep the connectors and terminals clean.
· 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.
· Avoid personal injury or equipment damage. Always keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors.

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SAFETY

WARNING
Alcohol and Drug Hazard
Never operate the generator set while you are under the influence of alcohol or drugs or are feeling ill.
Exposure Hazard
To avoid injury, always wear personal protective equipment including appropriate clothing, gloves, work shoes, eye and hearing protection as required by the task at hand.
Slip and Trip Hazard
Keep the generator free of oil, mud and other foreign matter.
Remove anything that creates slippery areas around the generator.
Sudden Movement Hazard
· Never attach tools or appliances to the generator before it is started. Starting the generator may cause sudden movement of the equipment. Disconnect any tools and appliances from the generator before starting.
· Before you start the engine make sure that all bystanders are clear of the area.
· Check before starting the engine that any tools or shop rags used during maintenance have been removed from the 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-resistant gloves.
· Never remove shields present on generator set. Ordinary maintenance activities can be safely carried out with shields assembled.
· Before starting any maintenance activity, let the generator set components (such as muffler) cool down for at least 20 minutes
Tool Hazard
Avoid personal injury or equipment damage. Always remove any tools or shop rags used during maintenance from the area before operation.
Exhaust Hazard
Avoid serious injury or death. Always ensure that all connections are tightened to specifications after repair is made to the exhaust system. All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning.

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CAUTION
Flying Object Hazard
· Avoid personal injury. Always wear eye protection when servicing the generator set or when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.
· Avoid personal injury. Always wear eye protection when servicing the engine or when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.
Poor Lighting Hazard
Avoid personal injury or equipment damage. Ensure that the work area is adequately illuminated. Always install wire cages on portable safety lamps.
Tool Hazard
Avoid personal injury or equipment damage. Always use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts.
Before starting the engine, always turn the switches on the working appliances (lighting apparatus, motor, etc.) to their OFF position. If the switches are not OFF, the sudden application of load when the engine is started could be very dangerous.

SAFETY
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 avoid its warranty. Always use YANMAR genuine replacement parts.
Always be environmentally responsible. Follow the guidelines of the governmental agencies for the proper disposal of hazardous materials such as engine oil, and diesel fuel. Consult the local authorities or reclamation facility.
Contact your authorized YANMAR industrial engine dealer or distributor if you need to operate the engine at high altitudes. At high altitudes the engine will lose power, run rough, and produce exhaust gases that exceed the design specifications.
· Always use correct polarity when you connect battery cables to the battery. This generator uses a negative ground, 12 VDC starting system.
· Make sure battery terminals are clean.
· Make sure cable connections are tight.
· Always shut down engine before removing or attaching battery cables.

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SAFETY

NOTICE
If you remove battery from generator, insulate the terminal on the end of the red, positive (+) battery cable. If the terminal is not insulated, it may spark when generator runs. Sparks may cause damage to the generator’s electronic circuits
Never operate the generator if it vibrates at high levels, if engine speed changes greatly or if the engine misfires often.
Never use an engine starting aid such as ether. Engine damage will result.
Always make sure the generator is operated on a level surface. If operated at an angle greater than 20° (in any direction) the battery could leak fluid. The generator must be on a flat level surface when checking the battery fluid level. If an engine runs for short periods of time (less than three minutes) at an angle greater than 25° in any direction, engine oil may enter the combustion chamber causing excessive engine speed and generate white smoke. This may cause serious engine damage.
Always run the engine at full speed. Never run engine at lower speeds. At full speed, the engine runs at 3000 (or 3600) min-1 (rpm) under load. The engine must maintain 3000 (or 3600) min-1 (rpm) for generator to create correct voltage. Running engine at lower speeds will damage generator and powered 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).
· If the ambient temperature exceeds +113 °F (+35 °C) the engine may overheat and cause the engine oil to break down.
· If the ambient temperature is below +5 °F (-15 °C) the engine will be hard to start and the engine oil may not flow easily.
Contact your authorized YANMAR industrial engine dealer or distributor if the engine will be operated outside of this standard temperature range.
Observe the following environmental operating conditions to maintain generator set performance and avoid premature engine wear:
· Avoid operating in extremely dusty conditions.
· Avoid operating in the presence of chemical gases or fumes.
· Avoid operating in a corrosive atmosphere such as salt water spray.
Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced.
Always tighten components to the specified torque. Loose parts can cause equipment damage or cause it to operate improperly.

Only use replacement parts specified. Other replacement parts may affect warranty coverage.

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NOTICE
If any indicator illuminates during engine operation, stop the engine immediately. Determine the cause and repair the problem before you continue to operate the engine.
Never operate the generator if:
· Engine speed changes greatly
· Engine misfires often
· Powered items overheat
· Electrical output drops
· It is sparking
· It produces smoke or flames
· It vibrates at high levels
· It has a damaged 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 signals.
When the engine is operated in dusty conditions, clean the air cleaner element more frequently. Never operate the engine with the air cleaner element(s) removed. This may cause foreign material to enter the engine and damage it.

SAFETY

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SAFETY
FORESEEABLE MISUSE
Foreseeable misuse and improper applications include, but are not limited to, the following:
– Operation not in compliance with the instructions given into this manual.
– Operation not in compliance with safety 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 environments.
– Operation in closed-off or poorly ventilated rooms.

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YDG Operation Manual

PRODUCT YDG Operation Manual
OVERVIEW
YANMAR YDG DIESEL GENERATOR FEATURES AND APPLICATIONS
To achieve the highest performing miniaturized and light-weight diesel engines, YANMAR CO., LTD. developed the LV 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 industrial diesel generator.

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PRODUCT OVERVIEW
COMPONENT IDENTIFICATION
YDG3700V-5(E)BYI2 and YDG3700N-6(E)BYI2 (Typical model)

1 23 4

5

7

89

10 11

12

13 6
14 15

22

21

20

19 18 17 16

1 ­ Muffler 2 ­ Starter solenoid (only for electric version) 3 ­ Starter motor (only for electric version) 4 ­ Engine nameplate decal 5 ­ Frame 6 ­ Control panel 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)
Figure 1

12

YDG Operation Manual

PRODUCT OVERVIEW
34127
YDG5500V-5(E)BYI2 and YDG5500N-6(E)BYI2 (Typical model)

12 3 4

5

7

89

10 11

12

13 6
14 15

22

21

20

19 18 17 16

06346 -00X00

1 ­ Muffler 2 ­ Starter solenoid (only for electric version) 3 ­ Starter motor (only for electric version) 4 ­ Engine nameplate decal 5 ­ Frame 6 ­ Control panel 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)
Figure 2

YDG Operation Manual

13

PRODUCT OVERVIEW
LOCATION OF LABELS
Safety Decals
YDG3700V-5(E)BYI2, YDG5500V-5(E)BYI2, YDG3700N-6(E)BYI2, YDG5500N-6(E)BYI2
DIESEL FUEL ONLY
DO NOT USE GASOLINE

14

H L

CAUTION

DIESEL FUEL FLAMMABLE
ENGINE MUST BE TURNED OFF WHEN ADDING FUEL DO NOT OPERATE THE ENGINE INDOORS OR IN POORLY VENTILATED PLACES. “SLOW” POSITION : NO LOAD ONLY

CHECK THE ENG -INE OIL (CC CLASS) SAE 10W30 (OIL CHANGE EYE
-RY 100hr.
H L

DO NOT OPERATE THE ENGINE IN STAND WATER OR RAIN

READ OPERATION MANUAL FOR COMPLETE INSTRUCTIONS.

OPERATION

CHECK FUEL AND ENGINE OIL LEVEL BEFORE STARTING. (OPEN THE FUEL COCK) MOVE THE ENGINE SPEED LEVEL TO THE “RUN” POSITION.

STARTING (RECOIL) 1) PULL THE STARTING ROPE SLOWLY UNTIL
YOU FEEL RESISTANCE, RETURN ROPE. 2) PUSH THE DECOMPRESSION LEVER DOWN. 3) PULL THE STARTER ROPE HARD AND FAST,
ALL THE WAY OUT. (ELECTRIC)

(RECOIL) RETURN ENGINE SPEED LEVER TO “STOP” POSITION. (ELECTRIC) TURN KEY TO “OFF” POSITION. (CLOSE FUEL COCK.)

WARM UP ENGINE FOR ABOUT 5 MINUTES.

View Y

Y

LOW OIL WARNING
IN THE CASE OF AUTO-STOP, DO NOT RUN WITHOUT CHECKING OIL LEVEL

CHECK ENGINE OIL EACH TIME FUEL TANK IS FILLED SAE 10W30(CC CLASS)

Figure 3

YDG Operation Manual

34127
Generator Set Decal

PRODUCT OVERVIEW

The YDG generator set model and serial number information decal is located inside the top front frame rail.

DIESEL FUEL ONLY
DO NOT USE GASOLINE

CAUTION

DIESEL FUEL FLAMMABLE
ENGINE MUST BE TURNED OFF WHEN ADDING FUEL DO NOT OPERATE THE ENGINE INDOORS OR IN POORLY VENTILATED PLACES. “SLOW” POSITION : NO LOAD ONLY

CHECK THE ENG -INE OIL (CC CLASS) SAE 10W30 (OIL CHANGE EYE
-RY 100hr.
H L

DO NOT OPERATE THE ENGINE IN STAND WATER OR RAIN

READ OPERATION MANUAL FOR COMPLETE INSTRUCTIONS.

OPERATION

CHECK FUEL AND ENGINE OIL LEVEL BEFORE STARTING. (OPEN THE FUEL COCK) MOVE THE ENGINE SPEED LEVEL TO THE “RUN” POSITION.

STARTING (RECOIL) 1) PULL THE STARTING ROPE SLOWLY UNTIL YOU FEEL RESISTANCE, RETURN ROPE. 2) PUSH THE DECOMPRESSION LEVER DOWN. 3) PULL THE STARTER ROPE HARD AND FAST, ALL THE WAY OUT. (ELECTRIC)

726723(1*,1(
(RECOIL) RETURN ENGINE SPEED LEVER TO “STOP” POSITION. (ELECTRIC) TURN KEY TO “OFF” POSITION. (CLOSE FUEL COCK.)

WARM UP ENGINE FOR ABOUT 5 MINUTES.

Yanmar Italy S.p.A Via Camperio, 9 – 20123 Milano, Italia

Low power generating set model: A Serial Number: B
Performance Class: G2

Made in Italy: C Mass (dry): D

RATED (ISO 8528)

E kW

MAX (ISO 8528)

H kW

Frequency K Hz

FV

GA

IV

JA

Power Factor 1

RPM L

I.C. H

IP 23M

ALTIT. 100 m

TEMP. 25 ~C

Figure 4
Description of Generator Set Model Number
YDG 5500 V – 5 (E) B Destination
Starting system E: Electric starting No symbol: Manual starting
Frequency 5: 50Hz 6: 60Hz
Exhaust gas emission regulations V : Euro Stage V emission regulation N: No emission regulation
Type
Generator series

YDG Operation Manual

15

PRODUCT OVERVIEW
Generator Decal
The generator decal is located on the left side of the generator body.

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).

1

View Z Z
Figure 5

Figure 6

MODEL MAX. OUTPUT DISPLACEMENT ENGINE NO.

kW /

min-1
l

MADE IN ITALY
Figure 7

16

YDG Operation Manual

34127
FUNCTION OF MAJOR COMPONENTS

PRODUCT OVERVIEW

Components Air cleaner Dynamo
Low engine oil shutdown
Engine oil filter Side filler ports (engine oil) Fuel filters Fuel tank Oil cap/dipstick (engine oil) Starter motor Control panel
Generator

Functions
The air cleaner prevents airborne contaminants from entering the engine. Periodic replacement of the air cleaner filter element is necessary. See Periodic Maintenance Schedule on page 47 for the replacement frequency.
If the engine is equipped with electric start, a charging dynamo is located under the engine flywheel. The dynamo supplies regulated electricity to the engine systems and charges the battery while the engine is running.
The generator is equipped with a low oil shutdown feature. If the engine is run when it is low on oil, the oil pressure will drop. The oil pressure switch will sense the drop in pressure and activate the stop solenoid, which will shut the engine down. Once the oil level is corrected, and pressure is normal, the engine can be run again.
The engine oil filter removes contaminants and sediment from the engine oil. Periodic cleaning of the oil filter is necessary. See Periodic Maintenance Schedule on page 47 for the frequency of cleaning.
You can fill the crankcase with engine oil from either side of the engine depending upon which filler port is most convenient.
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.
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 necessary for combustion enters the fuel system. Any fuel that is not used for combustion is returned to the fuel tank.
The engine oil cap/dipstick combines the oil cap and dipstick in one assembly. The dipstick part of the assembly is used to determine the amount of engine oil in the crankcase.
The starter motor is powered by the battery. When you turn the key switch to the START position, the starter motor engages with the ring gear installed on the flywheel and starts the flywheel in motion.
The control panel houses all the controls, switches, terminals, outlets and meters for the generator. All electrical power created by the generator is directed to the control panel and output is sent through various outlets and terminals located on the control panel.
The generator is coupled to the engine to produce electrical power to operate various loads and or machines. The generator is constructed as a self-exciting single phase A/C, and is comprised of a stator, rotor, automatic voltage regulator, rectifier and housing components.

YDG Operation Manual

17

PRODUCT OVERVIEW
GENERATOR CONTROL PANEL
YDG3700V-5BYI2, YDG5500V-5BYI2, YDG3700N-6BYI2, YDG5500N-6BYI2

1

2

0

240

~ 0 V 200

3

7

6

5

4

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

18

YDG Operation Manual

PRODUCT OVERVIEW
34127
YDG3700V-5EBYI2, YDG5500V-5EBYI2, YDG3700N-6EBYI2, YDG5500N-6EBYI2

1

2

3

0

240

~ 0 V 200

4

8
1 ­ Voltage meter 2 ­ AC circuit breaker
(Generator main switch-circuit breaker) 3 ­ Engine start key switch 4 ­ DC circuit breaker (12 VDC output)

7

6

5

. 5 ­ 12 VDC output receptacle
(For 12 VDC battery charging only) 6 ­ Grounding terminal 7 ­ Schuko socket (230V) 8 ­ CEE socket (230V)
Figure 9

YDG Operation Manual

19

PRODUCT OVERVIEW

AIR COOLED ENGINE
The engine is air-cooled by a cooling fan. The cooling system consists of a fan attached to the flywheel. The fan blows air past the cooling fins on the cylinder head and cylinder, which are enclosed by shrouds that direct the air flow.
2

ENGINE CONTROLS – RECOIL

STARTER

1

The engines are equipped with a recoil and an electric starter. This section explains the controls available 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, Figure 10) helps you start the engine by reducing the effort needed to pull the recoil starter handle. The decompression lever will automatically return to the original position when the engine starts.

Figure 10

K0002447A-00X

20

YDG Operation Manual

34127
ENGINE CONTROLS – ELECTRIC STARTER
Key Switch
The generator is equipped with a three position key switch – OFF, ON, and START.

1

2

OFF

ON

PRODUCT OVERVIEW
START (3, Figure 11) – Turn 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 discharging of the battery.

3
START
STARTER SW
K0002413A-00X
Figure 11
OFF (key straight up and down) (1, Figure 11) When you turn the key to this position the engine shuts down. Electric current to the battery, low engine oil shutdown device and other electric devices is shut off. The key can be inserted and removed from this position.
ON (2, Figure 11) – This is the position the key will be in when the engine is running. After starting engine, key switch will automatically return to this position.

The engine speed control lever (1, Figure 12) is moved to the run position (2, Figure 12) for generator operation. To stop the generator, turn the key switch to the OFF position, or push down on the stop lever (3, Figure 12) and the speed control lever (1, Figure 12), which is spring-loaded, will move back to the stop position.
1 2
RUN STOP
3
K0002443A-00X
Figure 12

YDG Operation Manual

21

PRODUCT OVERVIEW This Page Intentionally Left Blank

22

YDG Operation Manual

BEFORE YOU YDG Operation Manual OPERATE
INTRODUCTION
This section of the Operation Manual 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.

YDG Operation Manual

23

BEFORE YOU OPERATE
BATTERY
Checking Battery Electrolyte Level
DANGER
Never check the remaining battery charge by shorting out the terminals. This will result in a spark and may cause an explosion or fire. Use a hydrometer to check the remaining battery charge.

WARNING
Batteries contain sulfuric 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 not start, recharge the battery.

· If the engine still will not start after charging, have

your authorized YANMAR industrial engine dealer

or distributor check the battery and the engine’s

1

starting system.

· If operating the machine where the ambient

temperature could drop to 14 °F (-10 °C) or less,

remove the battery from the machine at the end

of the day. Store the battery in a warm place until

2

the next use. This will help start the engine easily

at low ambient temperatures.

Figure 1
· When the amount of fluid nears the lower limit line (2, Figure 1), remove caps and fill with distilled water so it is at the upper limit line (1, Figure 1). If operation continues with insufficient battery fluid, the battery life is shortened, and the battery may overheat and explode. During the summer, check the fluid level more often than specified.

24

YDG Operation Manual

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.

BEFORE YOU OPERATE

(-)

(+)

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, Figure 3) first from battery.
2. Disconnect positive (+) cable (2, Figure 3) from battery last.

4. Connect the negative (­) clamp from the charger to the negative (­) terminal on the battery.

YDG Operation Manual

25

BEFORE YOU OPERATE

(-) 1

(+)

2

Figure 3
3. When connecting cables to battery connect the positive (+) cable (1, Figure 4) first.
CAUTION
When you install a battery, always use correct polarity when you connect battery cables to the battery. Always make sure the battery terminals are clean and tight.
4. Connect the negative (­) cable (2, Figure 4) to the battery last.

(-) 2

(+)

1

Figure 4

DIESEL FUEL
Diesel Fuel Specifications
Diesel fuel should comply with the following specifications. The table lists several worldwide specifications for diesel fuels.
NOTICE
Always use diesel fuels recommended by YANMAR for the best engine performance, to prevent engine damage. Only use clean diesel fuel.

Diesel fuel specification EN590:96 ISO 8217 DMX BS 2869-A1 or A2 JIS K2204 grade No.2 KSM-2610 GB252

Location European Union International United Kingdom Japan Korea China

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-handling equipment clean at all times.
· Poor quality fuel can reduce engine performance and/or cause engine damage.
· Fuel additives are not recommended. Some fuel additives may cause poor engine performance. Consult your YANMAR industrial engine dealer or distributor for more information.

26

YDG Operation Manual

34127
· Ash content not to exceed 0.01 % by volume.
· Carbon residue content not to exceed 0.35 % by volume. Less than 0.1 % is preferred.
· Total aromatics content should not exceed 35 % by volume. Less than 30 % is preferred.
· PAH (Polycyclic Aromatic Hydrocarbons) content should be below 10 % by volume.
· Metal content of Na, Mg, Si, and Al should be equal to or lower than 1 mass ppm. (Test analysis method JPI-5S-44-95)
· Lubricity: Wear mark of WS1.4 should be Max. 0.018 in. (460 µm) at HFRR test.
Bio-diesel fuels
In Europe and in the United States, as well as some other countries, non- mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels.
YANMAR approves the use of bio-diesel fuels that do not exceed a blend of 7 % (by volume) of FAME with 93 % (by volume) of approved mineral oil derived diesel fuel. Such bio-diesel fuels are known in the marketplace as B7 diesel fuels.
These B7 diesel fuels must meet certain requirements 1. The bio-fuels must meet the minimum
specifications for the country in which they are used.
· In Europe, bio-diesel fuels must comply with the European Standard EN14214 and EN590 (for Oxidation stability).
· In the United States, bio-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.

BEFORE YOU OPERATE
Precautions and concerns regarding the use of bio-fuels:
1. Free methanol in FAME may result in corrosion of aluminum and zinc FIE components.
2. Free water in FAME may result in plugging of fuel filters and increased bacterial growth.
3. High viscosity at low temperatures may result in fuel delivery problems, injection pump seizures, and poor injection nozzle spray atomization.
4. FAME may have adverse effects on some elastomers (seal materials) and may result in fuel leakage and dilution of the engine lubricating oil.
5. Even bio-diesel fuels that comply with a suitable standard as delivered, will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system, and/or fuel storage containers, may be necessary.
6. The use of bio-diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers, or bio-diesel fuels that have degraded as per the precautions and concerns above, may affect the warranty coverage of your engine. See YANMAR Limited Warranty on page i.

YDG Operation Manual

27

BEFORE YOU OPERATE Filling the Fuel Tank
DANGER
Only fill the fuel tank with diesel fuel. Filling the fuel tank with gasoline may result in a fire and will damage the engine, never refuel with the engine running.
1
2

ENGINE OIL
The YANMAR YDG generators are equipped with a low oil pressure stop device. This device stops the engine automatically when the oil pressure falls below the specified level and prevents engine seizure 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.

Figure 5

K0002458A-00X

1. Clean the area around the fuel cap.
2. Remove the fuel cap (1, Figure 5) from the fuel tank.

CAUTION
Never remove inlet fuel screen from the filler port when filling the fuel tank. If removed, dirt and debris could get into the fuel system causing it to clog.

3. Stop fueling when the fuel is at the same level as the red ring (2, Figure 5) at the bottom of the inlet fuel screen.
DANGER
Never overfill the fuel tank.

4. Replace the fuel cap and hand-tighten. Over-tightening the fuel cap will damage it.

Use an engine oil that meets or exceeds the following guidelines and classifications:
Service categories
· API service categories CD or higher
· ACEA service categories E-3, E-4, and E-5
· JASO service category DH-1
Definitions
· API classification (American Petroleum Institute)
· ACEA classification (Association des Constructeurs Européens d’Automobilies)
· JASO (Japanese Automobile Standards Organization)
Note:
· Be sure the engine oil, engine oil storage containers, and engine oil filling equipment are free of sediments and water.
· Change the engine oil after the first 50 hours of operation and then every 200 hours thereafter.
· Select the oil viscosity based on the ambient temperature where the engine is being operated. See the SAE service grade viscosity chart (Figure 6).
· YANMAR does not recommend the use of engine oil “additives”.

28

YDG Operation Manual

34127
Additional technical engine oil requirements:
The engine oil must be changed when the Total Base Number (TBN) has been reduced to 2.0. TBN (mgKOH/g) test method; JIS K-201-5.2-2 (HCI), ASTM D4739 (HCI).
Engine Oil Viscosity
Select the appropriate engine oil viscosity based on the ambient temperature using the SAE service grade viscosity chart in (Figure 6).
SAE 10W SAE 20W SAE 10W-30 SAE 15W-40 SAE 20 SAE 30 SAE 40 SAE 20W – 50
-4°F 14°F 32°F 50°F 68°F 86°F 104°F 122°F (-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C) (50°C)
K0000005A00
Figure 6

BEFORE YOU OPERATE
Checking Engine Oil
1. Make sure engine is level. 2. Remove oil cap/dipstick (1, Figure 7) from
either location and wipe with clean cloth.
NOTICE
Prevent dirt and debris 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 keep the oil level between the upper and lower lines on the oil cap/dipstick.
5. Fully reinsert oil cap/dipstick (1, Figure 7) and hand-tighten. Over- tightening the oil cap/dipstick will damage it.

1

2

3

4

Figure 7

YDG Operation Manual

29

BEFORE YOU OPERATE
Adding Engine Oil
1. Make sure engine is level. 2. Remove oil cap/dipstick (1, Figure 7). 3. Add indicated amount of engine oil at either one
of the engine oil filler ports (4, Figure 7). 4. Wait one minute and check oil level. 5. Add engine oil as needed until the level is
between the upper (2, Figure 7) and lower (3, Figure 7) lines on the oil cap/dipstick.
NOTICE
Never overfill. Overfilling may result in white exhaust smoke, engine overspeed or internal damage.

6. Fully reinsert oil cap/dipstick and hand-tighten. Over-tightening the oil cap/dipstick will damage it.
Engine Oil Capacity
The following table shows engine oil capacities for YANMAR YDG generators.

Engine/generator model
Engine L70V(N) generator YDG3700V(N)
Engine L100V(N) generator YDG5500V(N)

Dipstick upper limit/lower limit
1.11/0.69 qt (1.05/0.65 L)
1.7/1.06 qt (1.6/1.0 L)

GENERATOR CHECK
WARNING
Always have a licensed electrician connect the generator to the utility circuit. The generator must not be connected to other power sources. Improper installation can cause the generator to back-feed into the utility power line. This may electrocute a power company line 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.

Recommended minimum wire gauges (AWG) for extension cords

Ampere load

AWG for length of cord ft (m)
50 (15) 100 (30) 150 (46)

2

18

18

18

3

18

18

18

4

16

16

16

5

16

16

16

6

16

16

14

8

16

14

12

10

16

14

12

12

14

14

12

14

14

12

10

16

12

12

10

20

10

10

8

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 lug.
· Drive a grounding point into the ground. The grounding point can be a stake, grounding rod or pipe. The grounding point should be copper or brass.
CAUTION
Never use metal pipe that carries combustible materials or gases to ground the generator. Always ground the generator. Connect a length of heavy wire between the generator ground terminal and an external ground.

30

YDG Operation Manual

34127
· Attach the ground wire to the grounding point (1, Figure 8). You must supply the ground wire and grounding point. These are not supplied with the generator. Follow the local safety standards. Consult your power company or a licensed electrician.
YDG3700V-5B, YDG5500V-5B
YDG3700N-6B, YDG5500N-6B

BEFORE YOU OPERATE
. (1, Figure 9) shows the main AC switch on the YDG3700V-5B generator.
YDG3700V-5B, YDG5500V-5B YDG3700N-6B, YDG5500N-6B
1

0

240

~ 0 V 200

0

240

~ 0 V 200

1
Figure 8
3. Select the proper load for use with the generator set. See Selecting the Proper Load on page 32.
4. Before starting, always turn OFF 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.

Figure 9 (1, Figure 10) shows the main AC switch on the YDG5500V-5EB generators.
YDG3700V-5EB, YDG5500V-5EB YDG3700N-6EB, YDG5500N-6EB
1

0

240

~ 0 V 200

Figure 10

YDG Operation Manual

31

BEFORE YOU OPERATE
Selecting the Proper Load
CAUTION
· Never exceed the specified current limit for any one electrical terminal.
· Most home utility electric service is more than 60 amps. This generator will not power your entire home. This will exceed generator output. Only power items needed during a power outage. Always ensure total wattage of electrical load does not exceed rated wattage of generator.
NOTICE
Most electric appliances require more than their rated wattage for start-up.
The following appliance wattage table shows wattage of some common household appliances. This should be used as a generic guide only. Different manufacturers of certain products may require more wattage. See your authorized YANMAR industrial engine dealer or distributor with any questions.
Decide what electrical load your generator can power. Do this before using the generator. Use the following four step method. It will help to select a load that is not too large. Make sure total wattage of all electrical loads does not exceed the rated output capacity of your generator.
1. Make two lists of items you want powered by the generator. List all motors and motor powered appliances in one. List 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. Note: The nameplate may not list wattage. It may only list volts and amps.
· The formula for finding wattage is: volts amps = watts.
· For example, an appliance nameplate states 3 amps at 220 volts: 3 amps 220 volts = 660 watts.
3. Electric motors present a special problem when figuring load as they require up to three times their rated wattage to start. · For example, an electric motor nameplate states 5 amps at 220 volts. 5 amps 220 volts = 1100 watts: Running Watts
Multiply this by 3. This will show the starting watts needed.
1100 watts 3 = 3300 watts: Starting Watts
NOTICE
When figuring the generator load for motors, you must use the Starting Watts and not the Running Watts.
Note: Some motors require nearly the same wattage to run as to start. These items include saws, drills, hair dryers and food mixers.
4. Add running watts and starting watts of all items. This total must not exceed the rated output capacity of your generator. It is a good idea to have up to 25 % extra capacity for future needs or extra equipment.

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Typical electrical appliance wattages
Application/equipment Light bulb (100 W) AM/FM radio CB radio Fan Television Microwave oven Air conditioner (12,000 BTU) Furnace fan (1/3 hp blower motor) Vacuum cleaner Sump pump (1/3 hp) Refrigerator/freezer Deep freezer Circular saw Circular saw 6 in. Floodlight Drill 1/2 in. electric Toaster Coffee maker Skillet Chain saw 14 in. electric Water well pump (1/2 hp) Hot plate/range (per burner) Table saw 10 in. Water heater (storage type) 12 VDC battery charger

BEFORE YOU OPERATE

Running/rated watts 100
50 – 200 50 200
300 – 400 700 3250 600 600 700 800 500
1000 – 2500 800 1000 1000 1200 1200 1200 1200 1000 1500 2000 5000 120

Starting/surge watts 100
50 – 200 50 600
300 – 400 1000 5000 1800 750 2100 2400 1500
2300 – 4600 1000 1000 1250 1200 1200 1200 1500 3000 1500 6000 5000 120

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33

BEFORE YOU OPERATE
INITIAL ENGINE START UP
NOTICE
On the initial engine start-up, allow the engine to run without a load for approximately 15 minutes while you check for abnormal noises or vibration, diesel fuel leaks, engine oil leaks, and for proper operation.
Avoid continuous operation at maximum load for the remainder of the first hour of operation.
During the first 10 hours of operation, check the engine oil level frequently. See Checking Engine Oil on page 29.
DAILY CHECKS
Before you operate, make sure the YANMAR YDG generator is in good operating condition. Make sure you check the following items before you start your generator and have any repairs completed before starting the generator.
CAUTION
It is important to perform daily checks as periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine performance 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. Never check for a fuel leak with your hands. Always use a piece of wood or cardboard. Have your authorized YANMAR dealer or distributor repair the damage.
3. Check for damaged or missing parts. 4. Check for loose, missing or damaged fasteners. 5. Check the electrical harnesses for cracks,
abrasions and damaged or corroded connectors. 6. Check hoses for cracks, abrasions and damaged, loose or corroded clamps.
Check Battery Electrolyte Level
Follow the procedures in Checking Battery Electrolyte Level on page 24 to check the battery levels.
Check Diesel Fuel and Engine Oil Levels
Follow the procedures in Filling the Fuel Tank on page 28 and Checking Engine Oil on page 29 to check these levels.

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YDG Operation Manual

GENERATOR [ FI “Qr gtcvkqp”Ocpwcn OPERATION
INTRODUCTION
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.

YDG Operation Manual

35

GENERATOR OPERATION
STARTING THE GENERATOR
CAUTION
During manual starting operation, a knockback from recoil could happen, with risk of serious injuries, if proper starting procedure is not carried on. Be assured to read and understand starting manual procedure.

. 5. Move the engine control lever (1, Figure 24) to the RUN position (2, Figure 24).
1 2
RUN STOP

Recoil Start
Use the following procedure to start the engine using the recoil 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 Generator Check on page 30.
4. Turn the key clockwise from the OFF position (1, Figure 23) to the ON position (2, Figure 23).
1

OFF

2
ON

K0001355A
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 starter handle to the
initial position. 9. Push the decompression lever (2, Figure 25)
down until it locks in place and then release it.
CAUTION
Always depress the decompression lever to allow the engine to start more quickly and prevent damage to the recoil starter.
The decompression lever will automatically return to the original position when the engine starts.

START

STARTER SW

Figure 23

K0002413C-00X

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34127
2
1
K0002447A-00X
Figure 25 10. Grasp the recoil starter handle (1, Figure 25). 11. Pull the handle all the way out with a strong and
even motion. Use two hands if necessary.
NOTICE
Always pull recoil starter handle all the way out or the engine will not start. Pulling out the recoil starter handle too hard or fast will damage the equipment. Never allow the recoil starter handle to snap back against the engine. Return the handle to the starting position gently to prevent damage to the recoil starter.
12. Slowly return the recoil starter handle to the initial position.
13. If the engine does not start, repeat this procedure from Step 5.

GENERATOR OPERATION
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 Generator Check on page 30. 4. Move the engine speed control lever (1, Figure 26) to the RUN position (2, Figure 26).
1 2
RUN STOP
K0001355A
Figure 26 5. Insert the key into the key switch. 6. Turn the key clockwise to the START position
(1, Figure 27). Release the key as soon as the engine starts. It will return to the ON position (2, Figure 27).
NOTICE
Never hold the key in the START position for longer than 15 seconds or the starter motor will overheat.

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37

GENERATOR OPERATION

OFF

2
ON

1
START
STARTER SW
K0002413B-00X
Figure 27 7. If the engine fails to start:
· Wait until the engine comes to a complete stop before you attempt to start it again.
NOTICE
Engaging the starter while the engine is still rotating will result in damage to the starter motor and flywheel.
· Wait at least 30 seconds before you attempt to start the engine again.
NOTICE
Waiting 30 seconds will allow the battery voltage to recover to prevent damage to the starter motor due to the low battery voltage.

CHECKING THE GENERATOR SET DURING OPERATION
1. Check for fuel or engine oil leaks. If any leaks are found, shut down the engine and have the necessary repairs performed.
2. Check for abnormal sounds or vibration. If the abnormal sounds or vibration cannot be resolved, shut down the engine and 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 industrial engine dealer or distributor.
4. Check the fuel level during operation. If the fuel level runs low, stop the engine and refuel. See Filling the Fuel Tank on page 28.
5. If the oil pressure falls below the specified minimum, the low oil pressure shutdown will automatically stop the engine. Check the oil level and refill. See Checking Engine Oil on page 29.
6. If the engine suddenly stops, See Troubleshooting on page 62, then re-make the starting procedure. If the failure remains, contact your authorized YANMAR industrial engine dealer or distributor.

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Low Load Operation
Avoid low load operation as much as possible. Always operate at 1/4 load or greater when possible.
NOTICE
Always run the engine at full speed. Never run engine at lower speeds. At full speed, the engine runs at 3000 (3600) min-1 under load. The engine must maintain 3000 (3600) min-1 for generator to create correct voltage. Running engine at lower speeds will damage generator and powered items.
Operating at 1/4 load or less for extended periods will cause carbon to mix with unburned fuel, clogging the head of the injection nozzle and piston head and fouling the muffler. Carbon buildup can be recognized by bluish white smoke being emitted from the engine. To avoid this, run the engine at 3/4 load or greater for 30 minutes or longer every 50 hours operation.

GENERATOR 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 slightly before the engine itself is shut down.

Follow these steps to shut down the engine:
1. Turn the generator main AC switch (1, Figure 28) OFF.
2. With the engine speed lever in the RUN position, operate the engine without load for about five minutes.
3. Turn the generator key switch (2, Figure 28) to OFF.
YDG3700V-5EB, YDG5500V-5EB, YDG3700N-6EB, YDG5500N-6EB

1

2

0

240

~ 0 V 200

Figure 28
4. If the engine will not be used for six months or longer, follow the additional instructions in Long-Term Storage on page 69.

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39

GENERATOR OPERATION
AC APPLICATION
1. Start the engine. See Starting the Generator on page 36. Once the engine is started, make sure the voltage meter (1, Figure 29) or (1, Figure 30) indicates the voltage. If it does not, STOP the generator as the generator or voltage meter may be damaged.
YDG3700V-5B, YDG5500V-5B, YDG3700N-6B, YDG5500N-6B
1

0

240

~ 0 V 200

2. Plug in the appliance.
CAUTION
Always ensure that all appliances 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 distribution networks the resistance value shall not exceed 1,5 Ohm.

Figure 29 YDG3700V-5EB, YDG5500V-5EB YDG3700N-6EB, YDG5500N-6EB
1

3. Turn the main AC switch to the ON position.
NOTICE
If an overload trips the AC circuit protector, reduce the electrical load on the circuit and wait a few minutes before resuming operation.

0

240

~ 0 V 200

Figure 30

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DC APPLICATION
NOTICE
DC terminals should be used for charging 12 VDC batteries only. Using the DC terminals for any other type of 12 VDC appliance may cause damage to generator and appliance.
The DC terminal (1, Figure 31) may be used for charging 12 volt automotive- type batteries only. (Other loads may not be used.)
NOTICE
Never use the 12 VDC terminals at the same time as the AC terminals.
1. Always disconnect the negative (­) battery cable (if connected) from the battery to be charged 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 serious damage to the generator and or battery may occur. Do not attempt to start an automobile engine while the generator is still connected to the battery as the generator may be damaged.

GENERATOR OPERATION
YDG3700V-5EB, YDG5500V-5EB YDG3700N-6EB, YDG5500N-6EB

0

240

~ 0 V 200

1 1 ­ 12 VDC output terminal
(for 12 VDC battery charging only)
Figure 31

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41

GENERATOR OPERATION This Page Intentionally Left Blank

42

YDG Operation Manual

PERIODIC YDG Operation Manual 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.

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43

PERIODIC MAINTENANCE
PRECAUTIONS
The Importance of Periodic Maintenance
Engine deterioration and wear occurs in proportion to length of time the generator has been in service and the conditions the generator is subject to during operation. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor machine performance and helps extend the life of the engine.
CAUTION
Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated. Failure to follow these guidelines will impair the engine’s safety and performance characteristics, shorten the engine’s life and may affect the warranty coverage on your engine. See YANMAR Limited Warranty on page i. Consult your authorized YANMAR industrial engine dealer or distributor for assistance when checking items marked with a .
Performing Periodic Maintenance
Perform periodic maintenance procedures in an open, level area free from traffic. If possible, perform the procedures indoors to prevent environmental conditions, such as rain, wind, or snow, from damaging the machine.
The Importance of Daily Checks
Periodic maintenance schedules 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 Daily Checks
Keep a log of the number of hours the generator is run each day and a log of the daily checks performed. Also note the date, type of repair, and parts needed for any service needed between the periodic maintenance intervals. Periodic maintenance intervals are every 50, 200, 400, 1000, 1500 and 2000 hours of generator operation. Failure to perform periodic maintenance will shorten the life of the generator.
YANMAR Replacement Parts
Yanmar recommends that you use genuine YANMAR parts when replacement parts are needed. Genuine replacement parts help ensure long generator life. Replace circuit breakers only with components that have the same ratings and performance.
Tools Required
Before you start any periodic maintenance procedure make sure you have the tools you need to perform all of the required tasks.
Ask Your Authorized YANMAR Industrial Engine Dealer or Distributor for Help
YANMAR professional service technicians have the expertise and skills to help you with any maintenance or service related procedures.

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CAUTION
Before starting any maintenance procedure, ensure that the engine is cold and the speed control lever is set on STOP position.
Before 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.

PERIODIC MAINTENANCE
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.

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45

PERIODIC MAINTENANCE
TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS
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.
NOTICE
The tightening torque in the following chart should be applied only to the bolts with a “7” head. (JIS strength classification: 7T) Apply 60 % torque to bolts that are not listed. Apply 80 % torque when tightened to aluminum alloy.

Item Hexagon bolt (7T) and nut
PT plug
Pipe joint bolt

Nominal thread diameter pitch
M6 1.0 mm M8 1.25 mm M10 1.5 mm M12 1.75 mm M14 1.5 mm M16 1.5 mm
1/8 1/4 3/8 1/2 M8 M10 M12 M14 M16

Tightening torque

Remarks

7 – 9 lb-ft (87 – 104 lb-in., 9.8 -11.8 N·m, 1.0 – 1.2 kgf·m)
17 – 21 lb-ft (200 – 251 lb-in., 22.6 – 28.4 N·m, 2.3 – 2.9 kgf·m)
33 – 40 lb-ft (44.1 – 53.9 N·m, 4.5 – 5.5 kgf·m)
58 – 72 lb-ft (78.4 – 98.0 N·m, 8.0 – 10 kgf·m)
94 – 108 lb-ft (127.5 – 147.1 N·m, 13 – 15 kgf·m)
159 – 174 lb-ft (215.7 – 235.4 N·m, 22 – 24 kgf·m)
7 lb-ft (87 lb-in., 9.8 N·m, 1.0 kgf·m)
14 lb-ft (173 lb-in., 19.6 N·m, 2.0 kgf·m)
22 lb-ft (29.4 N·m, 3.0 kgf·m)
43 lb-ft (58.8 N·m, 6.0 kgf·m)
9 – 12 lb-ft (112 – 148 lb-in., 12.7 – 16.7 N·m, 1.3 – 1.7 kgf·m)
14 – 19 lb-ft (173 – 225 lb-in., 19.6 – 25.4 N·m, 2.0 – 2.5 kgf·m)
18 – 25 lb-ft (24.5 – 34.3 N·m, 2.5 – 3.5 kgf·m)
29 – 36 lb-ft (39.2 – 49.0 N·m, 4.0 – 5.0 kgf·m)
36 – 43 lb-ft (49.0 – 58.8 N·m, 5.0 – 6.0 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.
­
­

Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise specified.

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PERIODIC MAINTENANCE SCHEDULE

PERIODIC MAINTENANCE

Daily and periodic maintenance is important to keep the engine in good operating condition. The following is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary depending on engine application, loads, diesel fuel and engine oil used and are hard to establish definitively. The following should be treated only as a general guideline.

: Check
System Air intake Cylinder head
Electrical equipment
Emission control warranty
Engine oil
Engine speed control

: Replace : Contact your authorized YANMAR industrial engine dealer or distributor for these maintenance services

Periodic maintenance interval

Check item

Daily

Every 50 hours

Every 200
hours

Every 400
hours

Every 1000 hours

Every 1500 hours

Every 2000 hours

Clean or replace air

cleaner element – (may

need more frequent

service in dusty

conditions)

Adjust intake/exhaust valve clearance

Check compression

Check battery (if equipped) and add water as necessary

Before operation

Check battery indicator (if equipped) and other driven machine indicators (if equipped)

When engine is started

Wiring harness

Voltmeter

Inspect, clean and test

fuel injection nozzle, if

necessary

Check engine oil level and

add engine oil as

Before

necessary

operation

Drain and refill engine oil
Clean engine oil filter replace if damaged

1st time

2nd and
after

2nd and
after

Check for engine oil leakage

Before and after operation

Check for proper operation Verify adjustment

1st time

2nd and
after

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47

PERIODIC MAINTENANCE

: Check

: Replace

: Contact your authorized YANMAR industrial engine dealer or distributor for these maintenance services Periodic maintenance interval

System

Check item

Daily

Every 50 hours

Exhaust system

Check spark arrester for clogging (if equipped)

Before operation

Check fuel tank level and add fuel as necessary

Before operation

Drain and clean fuel tank

Fuel

Clean inlet fuel screen

Replace outlet fuel filter

Check for fuel leakage

Before and after operation

Every 200
hours

Hoses

Replace fuel system hose(s)

Every 400
hours

Every 1000 hours

Every 1500 hours

Every 2000 hours

or every 2
years whicheve r comes
first

Check brushes for wear or damage

Generator Frame

Check slip rings for wear or damage
Check coils and Automatic Voltage Regulator (AVR) for correct operation
Check main and sub frames for damage
Check engine/frame dampers for wear, damage and tightness
Check all fasteners for damage and tightness

Note: These procedures are considered normal maintenance and are performed at the owners expense.

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PERIODIC MAINTENANCE PROCEDURES
Daily, Before Operation

PERIODIC MAINTENANCE
Check engine speed control
Before you operate the driven machine check the engine speed control. See Check and adjust engine speed control on page 55.

Before performing periodic maintenance procedures, read the complete procedure including safety information.
Perform the following maintenance daily before operation.
· Check battery
· Check battery indicator
· Check engine oil level
· Check for engine oil leakage
· Check engine speed control (first time only)
· Check spark arrester
· Check fuel level
· Check for fuel leakage
Check battery
Check the battery electrolyte level. 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. If you discover any engine oil leaks, contact your authorized YANMAR industrial engine dealer or distributor for service.

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49

PERIODIC MAINTENANCE
Check fuel level
Before you operate the engine, check the fuel level. See Filling the Fuel Tank on page 28.

• Check for fuel leakage
  Before you operate the engine, check for any fuel leaks.
  DANGER
  Avoid personal injury. Always wear eye protection when checking for fuel leaks and never check for a fuel leak with your hands. Always use a piece of wood or cardboard. Have your authorized YANMAR dealer or distributor repair the damage.

Daily, After Operation
· 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 when checking for fuel leaks and never check for a fuel leak with your hands. Always use a piece of wood or cardboard. Have your authorized YANMAR dealer or distributor repair the damage.

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After Initial 50 Hours of Operation
Perform the following maintenance after the initial 50 hours of operation.
· Replace engine oil
· Clean/inspect engine oil filter
Replace engine oil
The engine oil on a new engine becomes contaminated from the initial break-in of internal parts. The initial 50 hour oil change and filter cleaning is very important.
Drain the engine oil as follows:
1. Make sure the engine is level. 2. Start the engine and bring it up to operating
temperature. 3. Stop the engine. 4. Position a container 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.

PERIODIC MAINTENANCE
1

2

3

4

Figure 32
6. Remove the oil cap/dipstick (1, Figure 32) to allow the engine oil to drain more easily.
NOTICE
Prevent dirt and debris from contaminating the engine oil. Carefully clean the oil cap/dipstick and the surrounding area before you remove the cap.
7. After all oil has been drained from the engine, reinstall the drain plug (2, Figure 32) and tighten to 173 – 208 lb-in. (19.6 – 23.5 N·m, 2.0 – 2.4 kgf·m).

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51

PERIODIC MAINTENANCE
. 8. Dispose of used oil properly.
NOTICE
Always be environmentally responsible. Follow the guidelines of the governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility. Never dispose of hazardous materials by dumping them into a sewer, on the ground or into ground water or waterways.

NOTICE
Never overfill. Overfilling may result in white exhaust smoke, engine overspeed or internal damage.
1

9. Inspect engine oil filter. See Clean/inspect engine oil filter on page 53.
10. Add engine oil until the level is between the upper (2, Figure 33) and lower (3, Figure 33) lines on the oil cap/dipstick (1, Figure 33). See Adding Engine Oil on page 30.

2

3

4

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 into the crankcase and turn clockwise for one-half revolution to engage the first thread in the crankcase opening. See Checking Engine Oil on page 29.
14. Add oil if necessary.
NOTICE
Always keep the oil level between the upper and lower lines on the oil cap/dipstick.

15. Replace the oil cap/dipstick and tighten by hand. Over-tightening may damage the cap. If any engine oil is spilled, wipe it away with a clean cloth.

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34127
Clean/inspect engine oil filter

3 21

4
K0001123B-00X
Figure 34
It is recommended that this procedure be performed at the same time as the Replace engine oil procedure on page 51.

1. Remove the oil filter retaining bolt (1, Figure 34).
2. Drain engine oil. See Replace engine oil on page 51.
3. Pull the oil filter cap (2, Figure 34) out and remove the oil filter (3, Figure 34).
4. Clean the oil filter in suitable parts cleaner or replace if damaged.
5. Lubricate the O-ring (4, Figure 34) with oil and reinstall the oil filter (3, Figure 34).

Applicable engine oil filter Part No.

L70V and L100V

114250-35070

6. Make sure the oil filter cap (2, Figure 34) is fully seated.
7. Reinstall and tighten the oil filter retaining bolt (1, Figure 34).
8. Add new engine oil to the engine as specified in Adding Engine Oil on page 30.

PERIODIC MAINTENANCE
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 crankcase and turn clockwise for one-half revolution to engage the first thread in the crankcase opening. See Checking Engine Oil on page 29.
12. Add oil if necessary.
NOTICE
Always keep the oil level between the upper and lower lines on the oil cap/dipstick.
13. Replace the oil cap/dipstick (1, Figure 33) and tighten by hand. Over- tightening may damage the cap. If any engine oil is spilled, wipe it away with a clean cloth.

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53

PERIODIC MAINTENANCE

Every 50 Hours of Operation
Perform the following maintenance every 50 hours of operation. · Clean inlet fuel screen · Test GFCI outlet
Clean inlet fuel screen
1. Clean the area around the fuel cap (1, Figure 35).
2. Remove the fuel cap from the fuel tank. 1 2 3
K0002456A-00X
Figure 35 3. Lift out the inlet fuel screen (3, Figure 35).
CAUTION
Wipe up all spills immediately.

Every 200 Hours of Operation
Perform the following maintenance every 200 hours of operation.
· 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 engine is operated in dusty conditions, clean the air cleaner element more frequently. Never operate the engine with the air cleaner element(s) removed. This may cause foreign material to enter the engine and damage it.
Clean or replace the air cleaner element if the air intake restriction exceeds the following specifications:
(L100V: 0.21 psi (1.47 kPa; 150 mmAq) or less), (L70V: 0.20 psi (1.37 kPa; 140 mmAq) or less).

4. Clean the inlet fuel screen using suitable parts cleaner or replace it if damaged.
5. Inspect fuel cap gasket (2, Figure 35) and replace if damaged.
6. Reinstall the inlet fuel screen.
7. Reinstall the fuel cap and hand-tighten. Over-tightening the fuel cap will damage it.

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L70V and 100V models
The L70V and 100V model engines use a “dry” type air filter element. The air filter element is an open paper type element. This type of air filter element should be cleaned or replaced every 200 hours or earlier if found excessively dirty.

PERIODIC MAINTENANCE

123

4

5

CAUTION
Avoid personal injury. Always wear eye protection when servicing the engine or when using compressed air or high pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.

1. Remove the wing nut (1, Figure 36).
2. Remove the air cleaner cover (2, Figure 36).
3. Remove the wing nut (3, Figure 36).
4. Remove the air cleaner element (4, Figure 36) and outer foam element (5, Figure 36).
5. Blow air through both elements using 42 – 71 psi (0.29 – 0.49 MPa, 3.0 – 5.0 kgf/cm2) compressed air to remove any debris. Blow air from the inside to the outside of the filter element using the lowest possible air pressure to remove dust without damaging the elements.
6. Check the condition of the air filter element by shining a flashlight from the back of the air filter element. If light is not visible on the outside of the air filter element, replace the air filter element.

Air cleaner element Part No.

L70V and L100V

114210-12590

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).

K0001549A-00X
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. Over-tightening the wing nut will damage the air cleaner assembly.
12. Reinstall the air cleaner cover (2, Figure 36).
13. Reinstall the wing nut (1, Figure 36) and hand-tighten. Over-tightening the wing nut will damage the air cleaner assembly.
Replace engine oil and clean/inspect engine oil filter
Change the engine oil every 200 hours of operation after the initial change at 50 hours. Clean and inspect the engine oil filter at the same time. See Replace engine oil on page 51 and Clean/inspect engine oil filter on page 53.
Check and adjust engine speed control
After you operate the engine for 200 hours, check the engine speed control.
Never attempt to adjust the low or high idle speed limit screw. This may impair the safety and performance of the machine and shorten its life. If adjustment is ever required, contact your authorized YANMAR industrial engine dealer or distributor.

YDG Operation Manual

55

PERIODIC MAINTENANCE
A constant speed control device is used on YDG generator sets, to govern the engine speed to a pre-set constant engine speed under various loads. When moved to the full throttle position, the speed control lever “locks” at full throttle.
Never force the throttle lever to move. This may deform the governor lever and cause irregular operation of the engine speed control.
Always run the engine at full speed. Never run engine at lower speeds. At full speed, the engine runs at 3000 (3600) min-1 under load. The engine must maintain 3000 (3600) min-1 for generator to create correct voltage. Running engine at lower speeds will damage generator and powered items.
1. Check that the speed control lever (1, Figure 37) operates smoothly and locks into the full speed RUN position (2, Figure 37) when advanced and returns to the stop position when the stop lever (3, Figure 37) is actuated. If the speed control lever does not operate as indicated or adjustment is needed, see your authorized YANMAR industrial engine dealer or distributor for service.
1 2
RUN
STOP
3
K0001355C-00X
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 combustibles or sources of ignition. Wipe up all spills immediately and never use a shop rag to catch spilled fuel.
2. Remove the fuel cap (1, Figure 38). 3. Remove the fuel tank drain plug (8, Figure 38)
and gasket (9, Figure 38) to drain the fuel. Inspect the gasket and replace if damaged.
NOTICE
Always be environmentally responsible. Follow the guidelines of the governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility.
4. Remove clamps (2, Figure 38) and disconnect fuel supply (3, Figure 38) and return lines (4, Figure 38).
5. Remove the fuel tank mounting bolts and remove the fuel tank from the generator frame.
6. Remove the three fuel filter nuts (5, Figure 38) and pull the fuel filter (6, Figure 38) out through bottom of the tank.

56

YDG Operation Manual

34127
1

9 8

7

2

4 6

2

5

3

K0002457B-00X

Figure 38
7. Install a new filter into the tank using a new O-ring (7, Figure 38).
8. Reinstall the three fuel filter nuts and tighten securely.
9. Reinstall the drain plug and gasket.
10. Reinstall the fuel tank into the generator frame and secure with mounting bolts.
11. Reconnect the fuel supply and return lines to the tank with clamps.
12. Fill the fuel tank with fuel and inspect for leaks. Repair or replace components as necessary.

PERIODIC MAINTENANCE
Every 400 Hours of Operation
Perform the following maintenance every 400 hours of operation.
· Adjust intake and exhaust valve clearance
· Check brushes for wear or damage
· Check slip rings for wear or damage
· Check coils and Automatic Voltage Regulator (AVR) for correct operation
· Check main and sub-frames for damage
· Check all fasteners for damage and tightness
Adjust intake and exhaust valve clearance
Proper 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 normal use of the generator over time. It is important to check the condition of the brushes to ensure generator performance is maintained at an optimum. See your authorized YANMAR industrial engine dealer or distributor for this service.
Check slip rings for wear or damage
Check the generator slip rings for wear and damage. Generator slip rings wear with normal use of the generator over time. It is important to check the condition of the slip rings to ensure generator performance is maintained at an optimum. See your authorized YANMAR industrial engine dealer or distributor for this service.

YDG Operation Manual

57

PERIODIC MAINTENANCE
Check coils and Automatic Voltage Regulator (AVR) for correct operation
Check the generator coils and AVR for correct operation and output. It is important to check the condition of the generator coils and AVR to ensure generator performance is maintained at an optimum. See your authorized YANMAR industrial engine dealer or distributor for this service.
Check main and sub-frames for damage
Check the main frame and sub-frames for damage. The main and sub-frames are the structural support for the engine, generator, fuel tank and all other generator controls and components. Any damage to the frames, including corrosion may compromise the structural integrity of the frame and should be repaired or replaced to avoid costly repairs and/or personal injury. See your authorized YANMAR industrial engine dealer or distributor for service and replacement parts.
Check all fasteners for damage and tightness
Check all fasteners used on the generator set. All fasteners should be 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.

Every 1000 Hours of Operation
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 hours to obtain optimum engine performance. See your authorized YANMAR industrial engine dealer or distributor for this service.
Check engine/frame dampers for wear, damage and tightness
Inspect all frame components for damage and repair or replace as required.
The damper mount butyl rubber has excellent shock absorption performance. Prevent contamination of the damper with diesel oil or gasoline as much as possible during operation, to prevent deterioration of the rubber damper. See your authorized YANMAR industrial engine dealer or distributor for service and replacement parts.
1. Check for separation at rubber baked portion (1, Figure 39).
2. Check the damper rubber material (2, Figure 39) for cracks and deformation. Replace the damper if cracked or deformed.

1 2

K0002858-00X
Figure 39

58

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34127
Every 1500 Hours of Operation
Perform the following maintenance every 1500 hours of operation.
· Inspect, clean and test fuel injection nozzle
Inspect, clean and test fuel injection nozzle, if necessary
Proper operation of the fuel injectors is required to obtain the optimum injection pattern for full engine performance. See your authorized YANMAR industrial engine dealer or distributor for this service.

PERIODIC MAINTENANCE
Every 2000 Hours of Operation
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. Rubberized fuel lines tend to dry out and become brittle after two years or 2000 hours of engine operation, whichever comes first.

YDG Operation Manual

59

PERIODIC MAINTENANCE
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.

60

YDG Operation Manual

[ F I “Qr gtcvkqp”Ocpwcn
TROUBLESHOOTING

TROUBLESHOOTING INFORMATION
If your generator does not operate properly, refer to the Troubleshooting Chart on page 62 or see your authorized YANMAR industrial engine dealer or distributor. You can refer to Troubleshooting Chart on page 62 even if your generator suddenly stops.
Provide the authorized YANMAR industrial engine dealer or distributor with the following information:
1. Model name and serial number of your generator.
The YDG generator set model and 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 months).

4. Operating conditions when problem occurs: · Load on engine · Color of exhaust smoke · Type of diesel fuel · Type of engine oil · Any abnormal noises or vibration · Operating environment such as high altitude or extreme ambient temperatures
5. Maintenance history and previous problems. 6. Other factors that contribute to the problem.

YDG Operation Manual

61

TROUBLESHOOTING

TROUBLESHOOTING CHART
If a problem occurs, stop the engine immediately. Refer to the symptom column in the chart below to identify the problem.

Symptom Engine does not start
Starter motor operates but engine does not start
Engine starts with recoil starter but then stops Starter motor does not operate or rotates too slowly (engine can be turned manually) Engine cannot be turned manually White or black exhaust smoke
Black exhaust smoke
White exhaust smoke

Probable cause
No diesel fuel Engine control lever not in the RUN position Engine oil level low
Improper diesel fuel
Clogged engine oil filter
Clogged fuel filter
Poor fuel injection Compressed air leakage from intake/exhaust valves Faulty engine stop solenoid Key switch not in the ON position Battery needs charging Faulty cable connection at battery terminals Faulty starter switch Faulty starter motor Inner parts seized or damaged
Engine overloaded Clogged air cleaner element
Improper diesel fuel
Faulty spraying of fuel injection Excessive intake/exhaust valve clearance
Improper diesel fuel
Faulty spray pattern of fuel injection Fuel injection timing delay Engine burning oil

Action
Refuel fuel system Move engine control lever to the RUN position Check and fill oil to proper level Replace with recommended diesel fuel Replace engine oil filter
Replace fuel filter
See authorized YANMAR industrial engine dealer or distributor
Turn key to the ON position Check electrolyte, recharge
Clean terminals, retighten
See authorized YANMAR industrial engine dealer or distributor
Reduce load Clean element or replace
Replace with recommended diesel fuel See authorized YANMAR industrial engine dealer or distributor Replace with recommended diesel fuel
See authorized YANMAR industrial engine dealer or distributor

Refer to
Filling the Fuel Tank on page 28
­
­ Diesel Fuel Specifications on page
26 ­ Drain the fuel tank and replace outlet fuel filter on page 56 ­
­
­
­
­ Disconnecting and Connecting Battery Cables on page 25
­ ­
­
­ Clean air cleaner element on page 54 Diesel Fuel Specifications on page 26
­
­
Diesel Fuel Specifications on page 26
­
­ ­

62

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34127
Symptom Generator
No electricity generated
Lack of no-load voltage Too low or too high no-load voltage Too low load voltage Too high load voltage Unstable voltage Overheating Noisy alternator

TROUBLESHOOTING

Probable cause

Action

Refer to

Main switch is off

Turn main switch on

Equipment incorrectly connected to generator Defective AVR Winding short circulated or loose connections Electrical load too high Loss of residual magnetism Engine speed too low Defective rotor diode Defective stator Defective rotor Engine not running properly
Demagnetized machine AVR fuse interrupted Faulty AVR Winding failure Insulation failure
Wrong or incorrectly carried out connections Faulty AVR
Winding failure Faulty slip-ring
Faulty AVR
Possible overload
Faulty AVR
Faulty AVR
Protections activated
Possible overload
Alternator inlet or outlet openings are clogged
Bearing broken

Connect the equipment correctly
See authorized YANMAR industrial engine dealer or distributor Reduce electrical load See authorized YANMAR industrial engine dealer or distributor
See authorized YANMAR industrial engine dealer or distributor
See authorized YANMAR industrial engine dealer or distributor
See authorized YANMAR industrial engine dealer or distributor Check load current value See authorized YANMAR industrial engine dealer or distributor See authorized YANMAR industrial engine dealer or distributor Turn off and restart the equipment Check load current value See authorized YANMAR industrial engine dealer or distributor See authorized YANMAR industrial engine dealer or distributor

Generator Check on page 30 ­ ­ ­ ­ ­ ­
­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­ ­
­
­
­
­
­ ­
­
­

YDG Operation Manual

63

TROUBLESHOOTING
ELECTRICAL WIRING DIAGRAM
YDG3700V-5B, YDG5500V-5B, YDG3700N-6B, YDG5500N-6B

STOP SOLENOID

BU

RE

BU

RE

RELAY

RE

DC

BL

TERMINALS

–

DC BREAKER

BL

OIL

PRESSURE

BL SWITCH

–

GE + AC
COIL
GE

BL RE

ALTERNATOR AVR

FREQ. JUMPER

VOLTAGE TRIMMER

AC COIL AC COIL

BL BR BU

RE
AUX COIL

4P

ROTOR COIL

BL

VOLTMETER

AC BREAKER

V
BR

BR BU BU

BL

Black

RE

Red

BU

Blue

BR

Brown

GE

Grey

YE/GR Yellow/Green

Figure 40

BR

BU

YE/GR

AC 230 V

AC 230 V

SCHUKO SOCKET

CEE SOCKET

YE/GR EARTH
TERMINAL
YE/GR

64

YDG Operation Manual

65

YDG Operation Manual

Figure 41

STOP SOLENOID

BU

RE

BU RE

BL

BL

RELAY

RE

DC

BL

TERMINAL

–

DC BREAKER

BL OIL
PRESSURE
SWITCH BL

BL RE

KEY SWITCH OPERATION DIAGRAM

E B IG BAT ST

OFF

OFF

I I

II II

–

BAT

BAT

KEY

IG ST

SWITCH

B

IG
ST B

E

E

GR RE

YE

ALTERNATOR AVR

GE

AC

COIL

GE

FREQ. JUMPER

VOLTAGE TRIMMER

AC COIL AC COIL

BL BR BU

RE
AUX COIL

4P BL

ROTOR COIL
VOLTMETER

AC BREAKER

V
BR

GR/WH

STARTER

RECTIFIER

BL/RE

GR/WH BL

–

BATTERY

GR/WH

CHARGE COIL
GR/WH

BL

Black

RE

Red

YE

Yellow

GR

Green

BU

Blue

BR

Brown

GE

Grey

YE/GR Yellow/Green

BL/RE Black/Red

GR/WH Green/White

BR

BU

BU

BR

BU

AC 230 V SCHUKO SOCKET

YE/GR

AC 230 V CEE
SOCKET

GR/WH

YE/GR

EARTH TERMINAL

YE/GR

TROUBLESHOOTING
34127
YDG3700V-5EB, YDG5500V-5EB, , YDG3700N-6EB, YDG5500N-6EB

TROUBLESHOOTING

ELECTRICAL EQUIPMENTS’ CONNECTIONS
(under “Electrical Separation” condition)

THE GENSET MUST BE PLACED ON A NON CONDUCTIVE SURFACE (SEE ASIDE FIGURE)

INSULATING MATERIAL (I.E. WOOD, RUBBER, ETC.)

L1 PE N

L1 PE N

– x2 CLASS II EQUIPMENT; – NO GROUNDING;

L1 PE N

L1 PE N

L1 PE N

L1 PE N

L1 PE N

L1 PE N

– x1 CLASS I EQUIPMENT; – NO GROUNDING;
– x1 CLASS I EQUIPMENT; – x1 CLASS II EQUIPMENT; – NO GROUNDING;
NOT PERMISSIBLE – x2 CLASS I EQUIPMENT;

66

YDG Operation Manual

TROUBLESHOOTING
34127
(/(&75,&$/(48,30(176¶&211(&7,216 71VVWHPZLWK5&’

L1 PE N

L1 PE N

/ 1

:,5,1’,$5$0 )255&’127,1& /8′(‘,16&23(2) 6833/<

/HJHQG
&/$66,,(48,30(17 &/$66,(48,30(17 ($57+187 ($57+52’

YDG Operation Manual

67

TROUBLESHOOTING This Page Intentionally Left Blank

68

YDG Operation Manual

LONG-TERM [ FI “Qr gtcvkqp”Ocpwcn 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.

YDG Operation Manual

69

LONG-TERM STORAGE
BEFORE YOU PLACE THE GENERATOR IN LONG-TERM STORAGE
1. Perform the next periodic maintenance procedure. For example, if there are 10 hours remaining before the 200 hour maintenance, you should do the maintenance before you place the engine in storage. See Periodic Maintenance Schedule on page 47.
2. Start the engine. Allow the engine to run without load for approximately five minutes and then stop the engine.
3. Drain the engine oil while the engine is still warm and fill with new oil. See Replace engine oil on page 51.
4. Push the decompression lever down and hold it while slowly pulling the recoil starter two or three times. Do not start the engine.
5. Pull the decompression lever up. Pull the recoil starter slowly and stop when there is resistance. This procedure closes the intake and exhaust valves in the compression position and helps prevent rust.
6. Allow the engine to completely cool then drain the fuel tank or fill it completely.
7. Protect the air 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 store it in a dry place.
NOTICE
Always protect the air cleaner and electric components from damage when you use steam or high pressure water to clean the generator.

RETURNING THE ENGINE TO SERVICE
1. Perform the Daily Checks on page 34. 2. Start the engine. Allow the engine to run
without load for approximately 5 to 10 minutes while you check for: · abnormal noises or vibration · fuel and engine oil leaks
DANGER
Avoid personal injury. Always wear eye protection when checking for fuel leaks and never check for a fuel leak with your hands. Always use a piece of wood or cardboard. Have your authorized YANMAR dealer or distributor repair the damage.
3. Avoid prolonged operation at maximum load for the remainder of the first hour of operation.

12. Rotate the engine without starting, every four to six months.

70

YDG Operation Manual

[ F I “Qr gtcvkqp”Ocpwcn
SPECIFICATIONS

PRINCIPAL SPECIFICATIONS

Generator

Model Type Excitation Voltage regulation Frequency

Rated output

Generator

Rated voltage

Rated current

Power factor

Phase

No. of poles

Type of insulation

Bearing system

AC Output terminal
DC

AC Breaker
DC

Voltmeter

Emergency stop system

L

Dimension

W

H

Protection

Performance Class (ISO8528-8)

Quality Class (ISO8528-8)

Vibation Level

Dry weight

Generator unit

YDG3700N-6(E)BYI2

YDG5500N-6(E)BYI2

Revolving field-type AC generator (with brush)

Self-excited

Automatic Voltage Regulator (AVR)

60 Hz ±1% (±2% on transient)

3.4 kVA

5.2 kVA

DC12 V – 10 A

240 V ±2%

14.2 A

21.7 A

1.0

Single-phase

2

H-class

Ball bearing (grease-enclosed)

AC240 V/16 A

Terminal (-: Black, +: Red)

14 A (NFB)

22 A (NFB)

12 A (thermal breaker)

AC300 V

Engine stop device by low level oil sensor

650 mm

720 mm

496 mm

480 mm

530 mm

578 mm

IP23M

G2

B

Amp [Avg]1mm – Acc [RMS] 52.4m/s2 Amp [Avg]1mm – Acc [RMS] 55.5 m/s2

71 kg (81 kg)

96 kg (106 kg)

YDG Operation Manual

71

SPECIFICATIONS

Generator

Model Type Excitation Voltage regulation Frequency

Rated output

Rated voltage

Rated current

Power factor

Phase

No. of poles

Type of insulation

Bearing system

AC Output terminal
DC

AC Breaker
DC

Voltmeter

Emergency stop system

L

Dimension

W

H

Protection

Performance Class (ISO8528-8)

Quality Class (ISO8528-8)

Vibation Level

Dry weight

Generator unit

YDG3700V-5(E)BYI2

YDG5500V-5(E)BYI2

Revolving field-type AC generator (with brush)

Self-excited

Automatic Voltage Regulator (AVR)

50 Hz ±1% (±2% on transient)

3.0 kVA

4.5 kVA

DC12 V – 10 A

230 V ±2%

13 A

19.6 A

1.0

Single-phase

2

H-class

Ball bearing (grease-enclosed)

AC230 V/16 A

Terminal (-: Black, +: Red)

13 A (NFB)

20 A (NFB)

12 A (thermal breaker)

AC300 V

Engine stop device by low level oil sensor

650 mm

720 mm

496 mm

480 mm

530 mm

578 mm

IP23M

G2

B

Amp [Avg]1mm – Acc [RMS] 51.7m/s2 Amp [Avg]1mm – Acc [RMS] 54.7 m/s2

71 kg (81 kg)

96 kg (106 kg)

72

YDG Operation Manual

34127
Engine

Engine model

(Generator)

Type

Combustion system

No. of cylinders

Bore × stroke

Displacement

Compression ratio

RPM (min-1)

hp SAE Continuous rated output
kW

PS

RPM (min-1)

Max. rated output (net)

hp SAE kW

PS

High idling

RPM (min-1)

Fuel injection timing

bTDC by FIC

Valve clearance

PTO position

Direction of rotation

Fuel injection pump

Fuel injection nozzle

Valve opening pressure

Fuel selection

Fuel filter

Governor

Balancer shaft

Engine weight (dry)

with electric start without electric start

Cooling system

Lubricating system

Oil selection

Oil filter

Permissible angle of inclination

Air cleaner

Muffler

SPECIFICATIONS

L70N6-G(E)YDG2

L100N6-G(E)YDG2

YDG3700N-6(E)B

YDG5500N-6(E)B

4-stroke, vertical cylinder, air-cooled diesel engine

Direct injection

1

78 × 67 mm

86 × 75 mm

0.320 L

0.435 L

20

20

3600

3600

5.9

8.9

4.4

6.6

6.0

9.0

3000

3000

6.6

9.9

4.9

7.4

6.0

10

3800

3800

20°

20°

0.15 ± 0.05 mm

Crankshaft

Counterclockwise viewed from PTO side

­

­

200 kgf/cm2

See Diesel Fuel on page 26

5 µm

All speed type, mechanical

Single shaft

41.0 kg

53.5 kg

36.0 kg

48.5 kg

Forced air by flywheel fan

Forced lubrication with trochoid pump

See Engine Oil on page 28.

Resin, 60 mesh

20° (momentary 30°)

Dry-type paper element filter

Expansion silencer with cover

YDG Operation Manual

73

SPECIFICATIONS

Engine model

(Generator)

Starting system

L

Dimensions

W

H

Oil capacity

Upper limit Lower limit

Fuel tank capacity

Battery capacity

L70N6-G(E)YDG2

L100N6-G(E)YDG2

YDG3700N-6(E)B

YDG5500N-6(E)B

Electric start/recoil start

354 mm

367 mm

436 mm

459 mm

453 mm

492 mm

1.05 L

1.6 L

0.65 L

1.0 L

13.0 L

35 Ah

Note:
1. Engine rating conditions are as follows (SAE J1349, ISO 3046/1): · Atmospheric condition: Room temperature 77 °F (25 °C), atmospheric pressure 29.53 in. Hg (100 kPa, 750 mm Hg), relative humidity 30 % · Fuel temperature at fuel injector pump inlet: 104 °F (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

74

YDG Operation Manual

SPECIFICATIONS
34127

Engine model

(Generator)

Type

Combustion system

No. of cylinders

Bore × stroke

Displacement

Compression ratio

RPM (min-1)

hp SAE Continuous rated output
kW

PS
RPM (min-1)

Max. rated output (net)

hp SAE kW

PS

High idling

RPM (min-1)

Fuel injection timing

bTDC by FIC

Valve clearance

PTO position

Direction of rotation

Fuel injection pump

Fuel injection nozzle

Valve opening pressure

Fuel selection

Fuel filter

Governor

Balancer shaft

Engine weight (dry)

with electric start without electric start

Cooling system

Lubricating system

Oil selection

Oil filter

Permissible angle of inclination

Air cleaner

Muffler

L70V5-G(E)YDG2

L100V5-G(E)YDG2

YDG3700V-5(E)B

YDG5500V-5(E)B

4-stroke, vertical cylinder, air-cooled diesel engine

Direct injection

1

78 × 67 mm

86 × 75 mm

0.320 L

0.435 L

21.1

21.2

3000

3000

5.4

7.6

4.0

5.7

5.4

7.7

3000

3000

5.9

8.4

4.4

6.3

6.0

8.6

3175

3175

13.5°

13.0°

0.15 ± 0.05 mm

Crankshaft

Counterclockwise viewed from PTO side

­

­

200 kgf/cm2

See Diesel Fuel on page 26

5 µm

All speed type, mechanical

Single shaft

41.0 kg

53.5 kg

36.0 kg

48.5 kg

Forced air by flywheel fan

Forced lubrication with trochoid pump

See Engine Oil on page 28.

Resin, 60 mesh

20° (momentary 30°)

Dry-type paper element filter

Expansion silencer with cover

YDG Operation Manual

75

SPECIFICATIONS

Engine model

(Generator)

Starting system

L

Dimensions

W

H

Oil capacity

Upper limit Lower limit

Fuel tank capacity

Battery capacity

L70V5-G(E)YDG2

L100V5-G(E)YDG2

YDG3700V-5(E)B

YDG5500V-5(E)B

Electric start/recoil start

354 mm

367 mm

436 mm

459 mm

453 mm

492 mm

1.05 L

1.6 L

0.65 L

1.0 L

13.0 L

35 Ah

Note:
2. Engine rating conditions are as follows (SAE J1349, ISO 3046/1): · Atmospheric condition: Room temperature 77 °F (25 °C), atmospheric pressure 29.53 in. Hg (100 kPa, 750 mm Hg), relative humidity 30 % · Fuel temperature at fuel injector pump inlet: 104 °F (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

Basing on altitude working conditions a derating factor for available genset output power must be applied, according to the following graph:
DERATING PERCENTAGE vs ALTITUDE
0

-5

DERATING [%]

-10

-15

-20

-25 0

250 500 750 1000 1250 1500 1750 2000 ALTITUDE [m]

76

YDG Operation Manual

Yanmar Energy System Co., Ltd.
Umeda Gate Tower 1-9, Tsurunocho, Kita-ku, Osaka, Japan
Yanmar America Corporation
101 International Parkway Adairsville, GA 30103, U.S.A. TEL: +1-770-877-9894 FAX: +1-770-877-9009 https://www.yanmar.com/us/
Yanmar Europe B.V.
Brugplein11, 1332 BS Almere -de Vaart The Netherlands.
TEL: +31-36-5493200 FAX: +31-36-5493209 https://www.yanmar.com/eu/
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 Engine (Shanghai) Corporation Ltd.
1101-1106 Gopher Center Building, No.757 Meng Zi Road Shanghai, China P.R.C. 200023 TEL: +86-21-2312-0688 FAX: +86-21-6880-8682
http://www.yanmar-china.com/cn/
Yanmar South America Industria De Maquinas Ltda.
Av. Presidente Vargas 1400, Indaiatuba, S.P., Brazil, CEP: 13338-901 TEL: +55-19-3801-9224 FAX: +55-19-3875-3899, 2241 https://www.yanmar.com/br/
As of December 31, 2020
OPERATION MANUAL
ORIGINAL INSTRUCTIONS
YDG3700V-5BYI2, YDG3700V-5EBYI2, YDG5500V-5BYI2, YDG5500V-5EBYI2 YDG3700N- 6BYI2, YDG3700N-6EBYI2, YDG5500N-6BYI2, YDG5500N-6EBYI2
1st edition: October 2021
Issued by: YANMAR ITALY S.p.A. Edited by: YANMAR ITALY S.p.A. ENGINEERING DEPARTMENT

YANMAR ITALY S.p.A
http://www.yanmaritaly.it

YIYDG-EN0000 2021.10

References

• 洋马
• YANMAR
• YANMAR South America
• YANMAR
• YANMAR Singapore
• YANMAR USA

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