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OPERATION MANUAL DIESEL POWERED GENERATORS YDG series YDG3700N-6BYI2 YDG3700N-6EBYI2 YDG3700V-5BYI2 YDG3700V-5EBYI2 YDG5500N-6BYI2 YDG5500N-6EBYI2 YDG5500V-5BYI2 YDG5500V-5EBYI2 original instructions...
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We reserve the right to make any change at any time without notice. YANMAR is a registered trade- mark of YANMAR POWER TECHNOLOGY CO., LTD. in Japan, the United States and/or other countries.
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.
• 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.
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.
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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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Welcome to the world of YANMAR! • Constant efforts are made to improve the quality and performance of YANMAR products, so some YANMAR has been the leader in industrial diesel details included in this Operation Manual may engines for over 90 years. We developed the differ slightly from your generator.
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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:________________________________________________________________________ YDG Operation Manual...
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YANMAR ITALY s.p.a. Manufacturer: Address: 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:...
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INTRODUCTION This Page Intentionally Left Blank viii YDG Operation Manual...
What is Covered by this Warranty? ..........i How Long is the Warranty Period? ..........i What the Generator Owner must Do: ........... ii To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor: ..................ii What YANMAR will Do: ..............ii What is not Covered by this Warranty? ........
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TABLE OF CONTENTS Safety ....................... 1 Safety Precautions ................2 Foreseeable Misuse................10 Product Overview.................. 11 YANMAR YDG Diesel Generator Features and Applications ... 11 Component Identification ..............12 Location of Labels ................14 Safety Decals ................14 Generator Set Decal..............15 Description of Generator Set Model Number ......
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Keep a Log of Generator Hours and Daily Checks ..... 44 YANMAR Replacement Parts............44 Tools Required ................44 Ask Your Authorized YANMAR Industrial Engine Dealer or Distributor for Help............... 44 Tightening Fasteners..............45 Tightening Torques for Standard Bolts and Nuts ......46 Periodic Maintenance Schedule............
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TABLE OF CONTENTS This Page Intentionally Left Blank YDG Operation Manual...
[ F I "Qr gtcv k qp"Ocpwcn SAFETY YANMAR considers safety of great importance and CAUTION recommends that anyone that comes into close contact with its products, such as those that install, Indicates a hazardous situation which, if not operate, maintain or service YANMAR products,...
• See your authorized YANMAR dealer or • Never place diesel fuel, flammable material distributor for additional training. such as oil, hay or dried grass or chemical...
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SAFETY 341 27 connected to the sockets of the gen-set, DANGER unless double insulated ones (class II), must be equipped with PE conductor in order to Electric Shock Hazard ensure equipotential bonding between the • Always have a licensed conductive structural parts of gen-set and the electrician connect the generator appliances.
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SAFETY DANGER WARNING Fire Hazard Explosion Hazard • Never use metal pipe that carries • Avoid serious personal injury or combustible materials or gases to equipment damage. While the ground the generator. engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited.
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SAFETY 341 27 WARNING WARNING Entanglement Hazard Electrical Hazard • Rotating parts can cause severe • Make welding repairs safely. 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 •...
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SAFETY WARNING WARNING Alcohol and Drug Hazard Burn Hazard Never operate the generator set • Avoid serious injury. Some of the while you are under the influence of generator set surfaces become alcohol or drugs or are feeling ill. very hot during operation and shortly after shut down.
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Any alterations to this generator injure your eyes. set may avoid its warranty. Always use YANMAR genuine replacement parts. • Avoid personal injury. Always wear eye protection when servicing the engine or when using compressed air or high-pressure water.
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Sparks may cause damage • The standard range of ambient temperatures for to the generator's electronic circuits the normal operation of YANMAR engines is from +5 °F (-15 °C) to +113 °F (+35 °C). Never operate the generator if it vibrates at high •...
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SAFETY 341 27 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 •...
- 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.
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: •...
PRODUCT OVERVIEW COMPONENT IDENTIFICATION YDG3700V-5(E)BYI2 and YDG3700N-6(E)BYI2 (Typical model) 1 – Muffler 13 – Generator set model and serial number decal 2 – Starter solenoid (only for electric version) 14 – Engine control lever 3 – Starter motor (only for electric version) 15 –...
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PRODUCT OVERVIEW 341 27 YDG5500V-5(E)BYI2 and YDG5500N-6(E)BYI2 (Typical model) 19 18 06346 -00X00 1 – Muffler 13 – Generator set model and serial number decal 2 – Starter solenoid (only for electric version) 14 – Engine control lever 3 – Starter motor (only for electric version) 15 –...
PRODUCT OVERVIEW LOCATION OF LABELS Safety Decals YDG3700V-5(E)BYI2, YDG5500V-5(E)BYI2, YDG3700N-6(E)BYI2, YDG5500N-6(E)BYI2 D I E S E L F U E L ONL Y DO NOT USE GASOLINE C A U T I O N CHECK THE ENG DO NOT OPERATE D I E S E L F U E L -INE OIL (CC CLASS) THE ENGINE IN...
341 27 Generator Set Decal The YDG generator set model and serial number information decal is located inside the top front frame rail. Yanmar Italy S.p.A Via Camperio, 9 - 20123 Milano, Italia Low power generating set model: Made in Italy:...
PRODUCT OVERVIEW Generator Decal Engine Nameplate (Typical) The generator decal is located on the left side of The engine nameplate (Figure 7) is located on the the generator body. cooling shroud on the PTO side of engine above the starter (1, Figure 6). View Z Figure 6 Figure 5...
PRODUCT OVERVIEW 341 27 FUNCTION OF MAJOR COMPONENTS Components Functions The air cleaner prevents airborne contaminants from entering the engine. Periodic Air cleaner 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 Dynamo under the engine flywheel.
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.
PRODUCT OVERVIEW 341 27 ENGINE CONTROLS - ELECTRIC START (3, Figure 11) - Turn the key to this position to start the engine. As soon as the engine starts, STARTER release the key and it will automatically return to the ON position. Key Switch The generator is equipped with a three position key switch - OFF, ON, and START.
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PRODUCT OVERVIEW This Page Intentionally Left Blank 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.
• 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 starting system.
BEFORE YOU OPERATE 341 27 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.
The table lists several worldwide specifications for diesel fuels. Always use diesel fuels recommended by YANMAR for the best engine performance, to prevent engine damage. Only use clean diesel fuel. Figure 3 3. When connecting cables to battery connect the positive (+) cable (1, Figure 4) first.
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YANMAR approves the use of bio-diesel fuels that bio-diesel fuels that have degraded as per the do not exceed a blend of 7 % (by volume) of FAME...
See the SAE service grade viscosity chart Never overfill the fuel tank. (Figure 6). • YANMAR does not recommend the use of engine 4. Replace the fuel cap and hand-tighten. oil “additives”. Over-tightening the fuel cap will damage it.
BEFORE YOU OPERATE 341 27 Additional technical engine oil Checking Engine Oil requirements: 1. Make sure engine is level. The engine oil must be changed when the Total 2. Remove oil cap/dipstick (1, Figure 7) from Base Number (TBN) has been reduced to 2.0. TBN either location and wipe with clean cloth.
Ampere ft (m) Engine Oil Capacity load 50 (15) 100 (30) 150 (46) The following table shows engine oil capacities for YANMAR YDG generators. Dipstick Engine/generator model upper limit/lower limit Engine L70V(N) 1.11/0.69 qt generator YDG3700V(N) (1.05/0.65 L) Engine L100V(N) 1.7/1.06 qt...
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BEFORE YOU OPERATE 341 27 (1, Figure 9) shows the main AC switch on the YDG3700V-5B generator. • Attach the ground wire to the grounding point (1, Figure 8). You must supply the ground wire YDG3700V-5B, YDG5500V-5B and grounding point. These are not supplied with the generator.
1100 watts 3 = 3300 watts: Starting Watts Different manufacturers of certain products may require more wattage. See your authorized YANMAR industrial engine dealer or distributor with any questions. When figuring the generator load for motors, you must use the Starting Watts and not the Running Decide what electrical load your generator can Watts.
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BEFORE YOU OPERATE 341 27 Typical electrical appliance wattages Application/equipment Running/rated watts Starting/surge watts Light bulb (100 W) AM/FM radio 50 - 200 50 - 200 CB radio Television 300 - 400 300 - 400 Microwave oven 1000 Air conditioner (12,000 BTU) 3250 5000 Furnace fan (1/3 hp blower motor)
DAILY CHECKS 3. Check for damaged or missing parts. Before you operate, make sure the YANMAR YDG generator is in good operating condition. Make sure 4. Check for loose, missing or damaged fasteners. you check the following items before you start your 5.
GENERATOR [ F I "Qr gtcv k qp"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...
GENERATOR OPERATION STARTING THE GENERATOR 5. Move the engine control lever (1, Figure 24) to the RUN position (2, Figure 24). CAUTION During manual starting operation, a knockback from recoil could happen, with risk of serious injuries, if proper starting procedure is not carried on.
GENERATOR OPERATION 341 27 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.
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 START distributor. 3. Check for white or black smoke from the STARTER exhaust system.
Avoid low load operation as much as possible. Always operate at 1/4 load or greater when possible. For maximum engine life, YANMAR recommends that when shutting the engine down, you allow the Always run the engine at full speed. Never run engine to run, without load, for five minutes.
GENERATOR OPERATION AC APPLICATION 2. Plug in the appliance. 1. Start the engine. See Starting the Generator on CAUTION page 36. Once the engine is started, make sure Always ensure that all appliances are in good the voltage meter (1, Figure 29) or working order before connecting them to the (1, Figure 30) indicates the voltage.
GENERATOR OPERATION 341 27 DC APPLICATION YDG3700V-5EB, YDG5500V-5EB YDG3700N-6EB, YDG5500N-6EB 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.
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GENERATOR OPERATION This Page Intentionally Left Blank 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. YDG Operation Manual...
See YANMAR Replacement Parts YANMAR Limited Warranty on page i. Consult Yanmar recommends that you use genuine your authorized YANMAR industrial engine YANMAR parts when replacement parts are dealer or distributor for assistance when needed.
PERIODIC MAINTENANCE 341 27 Tightening Fasteners CAUTION Use the correct amount of torque when you tighten Before starting any maintenance procedure, fasteners on the machine. Applying excessive ensure that the engine is cold and the speed torque may damage the fastener or component and control lever is set on STOP position.
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. The tightening torque in the following chart should be applied only to the bolts with a “7”...
The following should be treated only as a general guideline. : Check : Replace : Contact your authorized YANMAR industrial engine dealer or distributor for these maintenance services Periodic maintenance interval Every Every Every Every...
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PERIODIC MAINTENANCE : Check : Replace : Contact your authorized YANMAR industrial engine dealer or distributor for these maintenance services Periodic maintenance interval Every Every Every Every Every System Check item Daily Every 1000 1500 2000 50 hours...
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. YDG Operation Manual...
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Avoid being burned by contact with hot engine Always use a piece of wood or cardboard. Have oil. your authorized YANMAR dealer or distributor repair the damage. Check for fuel leakage ...
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PERIODIC MAINTENANCE 341 27 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 Figure 32 contaminated from the initial break-in of internal parts.
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PERIODIC MAINTENANCE 8. Dispose of used oil properly. Never overfill. Overfilling may result in white exhaust smoke, engine overspeed or internal Always be environmentally responsible. Follow damage. the guidelines of the governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant.
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PERIODIC MAINTENANCE 341 27 Clean/inspect engine oil filter 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.
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PERIODIC MAINTENANCE Every 50 Hours of Operation Every 200 Hours of Operation Perform the following maintenance every 50 hours Perform the following maintenance every 200 hours of operation. of operation. • Clean inlet fuel screen • Clean air cleaner element •...
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8. Clean the inside of the air cleaner cover limit screw. This may impair the safety and (2, Figure 36). 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...
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Always be environmentally responsible. Follow indicated or adjustment is needed, see your the guidelines of the governmental agencies for authorized YANMAR industrial engine dealer or the proper disposal of hazardous materials such distributor for service. as engine oil, diesel fuel and engine coolant.
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7. Install a new filter into the tank using a new noisily, resulting in poor engine performance and O-ring (7, Figure 38). engine damage. See your authorized YANMAR 8. Reinstall the three fuel filter nuts and tighten industrial engine dealer or distributor for this securely.
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AVR to ensure generator performance is maintained at an • Check compression optimum. See your authorized YANMAR industrial • Check engine/frame dampers for wear, engine dealer or distributor for this service. damage and tightness Check main and sub-frames for damage ...
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2000 hours of engine operation, whichever comes performance. See your authorized YANMAR first, even if the engine has been out of service. industrial engine dealer or distributor for this Rubberized fuel lines tend to dry out and become service.
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. YDG Operation Manual...
If your generator does not operate properly, refer to • Type of diesel fuel the Troubleshooting Chart on page 62 or see your authorized YANMAR industrial engine dealer or • Type of engine oil distributor. You can refer to Troubleshooting Chart •...
Drain the fuel tank and Clogged fuel filter Replace fuel filter replace outlet fuel filter on page 56 Poor fuel injection – See authorized YANMAR Compressed air leakage from industrial engine dealer or – intake/exhaust valves distributor Faulty engine stop solenoid –...
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Turn main switch on page 30 Equipment incorrectly connected Connect the equipment correctly – to generator Defective AVR – See authorized YANMAR industrial engine dealer or Winding short circulated or loose – distributor connections Electrical load too high Reduce electrical load –...
TROUBLESHOOTING ELECTRICAL WIRING DIAGRAM YDG3700V-5B, YDG5500V-5B, YDG3700N-6B, YDG5500N-6B STOP SOLENOID ALTERNATOR RELAY PRESSURE FREQ. JUMPER SWITCH VOLTAGE TRIMMER AC COIL AC COIL TERMINALS COIL DC BREAKER ROTOR COIL COIL VOLTMETER BREAKER Black Blue YE/GR EARTH Brown TERMINAL Grey YE/GR YE/GR Yellow/Green YE/GR...
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STOP SOLENOID SWITCH ALTERNATOR STARTER RELAY GR/WH RECTIFIER BL/RE PRESSURE FREQ. JUMPER SWITCH VOLTAGE TRIMMER GR/WH AC COIL AC COIL BATTERY COIL TERMINAL DC BREAKER ROTOR COIL GR/WH COIL CHARGE COIL VOLTMETER GR/WH AC BREAKER GR/WH Black Yellow Green KEY SWITCH OPERATION DIAGRAM Blue IG BAT ST YE/GR...
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.) - x2 CLASS II EQUIPMENT; - NO GROUNDING; - x1 CLASS I EQUIPMENT; - NO GROUNDING;...
LONG-TERM [ F I "Qr gtcv k qp"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...
See Replace engine Always use a piece of wood or cardboard. oil on page 51. Have your authorized YANMAR dealer or distributor repair the damage. 4. Push the decompression lever down and hold it while slowly pulling the recoil starter two or three times.
[ F I "Qr gtcv k qp"Ocpwcn SPECIFICATIONS PRINCIPAL SPECIFICATIONS Generator Model YDG3700N-6(E)BYI2 YDG5500N-6(E)BYI2 Type Revolving field-type AC generator (with brush) Excitation Self-excited Voltage regulation Automatic Voltage Regulator (AVR) Hz ±1% (±2% on transient) Frequency 3.4 kVA 5.2 kVA Rated output DC12 V - 10 A V ±2%...
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SPECIFICATIONS Model YDG3700V-5(E)BYI2 YDG5500V-5(E)BYI2 Type Revolving field-type AC generator (with brush) Excitation Self-excited Voltage regulation Automatic Voltage Regulator (AVR) Hz ±1% (±2% on transient) Frequency 3.0 kVA 4.5 kVA Rated output DC12 V - 10 A V ±2% Rated voltage Rated current 13 A 19.6 A...
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SPECIFICATIONS 341 27 Engine Engine model L70N6-G(E)YDG2 L100N6-G(E)YDG2 (Generator) YDG3700N-6(E)B YDG5500N-6(E)B Type 4-stroke, vertical cylinder, air-cooled diesel engine Combustion system Direct injection No. of cylinders Bore × stroke 78 × 67 mm 86 × 75 mm Displacement 0.320 L 0.435 L Compression ratio RPM (min...
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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 •...
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SPECIFICATIONS 341 27 Engine model L70V5-G(E)YDG2 L100V5-G(E)YDG2 (Generator) YDG3700V-5(E)B YDG5500V-5(E)B Type 4-stroke, vertical cylinder, air-cooled diesel engine Combustion system Direct injection No. of cylinders Bore × stroke 78 × 67 mm 86 × 75 mm Displacement 0.320 L 0.435 L Compression ratio 21.1 21.2...
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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 •...
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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...
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