Yanmar YDG Series Operation Manual
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Yanmar YDG Series Operation Manual

Diesel powered generator
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YDG
series
OPERATION MANUAL
Diesel Powered Generators
YDG2700EV-6EH
YDG3700EV-6EI • YDG5500EV-6EI
YDG Operation Manual
P/N: 0AYDG0-G0000
INDUSTRIAL
ENGINES

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Summary of Contents for Yanmar YDG Series

  • Page 1 series OPERATION MANUAL Diesel Powered Generators YDG2700EV-6EH YDG3700EV-6EI • YDG5500EV-6EI YDG Operation Manual P/N: 0AYDG0-G0000 INDUSTRIAL ENGINES...
  • Page 2 Disclaimers: We reserve the right to change specifications and to improve our products without notice or obligation. Yanmar and are registered trademarks of Yanmar 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 Co., Ltd.

  • Page 3: Introduction

    INTRODUCTION YDG Operation Manual Welcome to the world of Yanmar! Yanmar has been • Constant efforts are made to improve the quality the leader in industrial diesel engines for over 90 and performance of Yanmar products, so some years. We developed the world’s first practical details included in this Operation Manual may small-sized diesel engine in 1933.

  • Page 4: Record Of Ownership

    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...

  • Page 5: Yanmar 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.

  • Page 6: What The Generator Owner Must Do

    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.

  • Page 7: What Is Not Covered By This Warranty

    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.

  • Page 8: Retail Purchaser Registration

    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.

  • Page 9: Emission System Warranty

    The California Air Resources Board (CARB), the Environmental Protection Agency (EPA) and Yanmar Co., Ltd. hereafter referred to as Yanmar, are pleased to explain the emission control system warranty on your industrial compression-ignition engine. In California, model year 2000 or later off-road compression- ignition engines must be designed, built and equipped to meet the State’s stringent anti-smog standards.

  • Page 10: Warranty Coverage

    Warranty Coverage: This warranty is transferable to each subsequent purchaser for the duration of the warranty period. Repair or replacement of any warranted part will be performed at an authorized Yanmar industrial engine dealer or distributor. Warranted parts not scheduled for replacement as required maintenance in the Operation Manual shall be warranted for the warranty period.

  • Page 11: Exclusions

    You are responsible for initiating the warranty process. You must present your engine to a Yanmar dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.
  • Page 12 YANMAR WARRANTIES This Page Intentionally Left Blank YDG Operation Manual...

  • Page 13: Table Of Contents

    What is Covered by this Warranty? ..........v How Long is the Warranty Period?..........v What the Generator Owner Must Do: ........... vi To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor: ..............vi What Yanmar Will Do: ..............vi What is Not Covered by this Warranty? ........
  • Page 14 TABLE OF CONTENTS Before You Operate ..............2 During Operation and Maintenance ..........2 Product Overview.................. 19 Yanmar YDG diesel Generator Features and Applications....19 Component Identification ..............20 Location of Labels ................23 Safety Labels YDG2700EV-6EH..........23 Safety Labels YDG3700EV-6EI, YDG5500EV-6EI ..... 24 Engine Label ................
  • Page 15 Keep a Log of Generator Hours and Daily Checks ..... 97 Yanmar Replacement Parts ............97 Tools Required ................97 Ask Your Authorized Yanmar Industrial Engine ......97 Dealer or Distributor For Help............97 Required EPA / ARB Maintenance - USA Only......97 Tightening Fasteners..............
  • Page 16 TABLE OF CONTENTS Electrical Wiring Diagram ..............121 Long Term Storage ................123 Introduction ..................123 Before You Place the Generator In Long Term Storage ....123 Returning the Engine to Service ............. 125 Specifications..................127 Principal Specifications ..............127 Generator ..................

  • Page 17: Safety

    SAFETY YDG Operation Manual SAFETY STATEMENTS WARNING Yanmar considers safety of great importance and Warning (the word “WARNING” is in recommends that anyone that comes into close black letters with an orange rectangle contact with its products, such as those that install, behind it) –...

  • Page 18: Safety Precautions

    • Failure to comply will result in death or • Machine safety signs and labels are serious injury. additional reminders for safe operating and maintenance techniques. 0000003en • See your authorized Yanmar industrial engine dealer or distributor for additional training. 0000002enGen YDG Operation Manual...
  • Page 19 SAFETY DANGER DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is extremely flammable and • Diesel fuel is extremely flammable and explosive under certain conditions. explosive under certain conditions. • When you remove any fuel system •...
  • Page 20 SAFETY DANGER DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Only use the key switch to start the • Diesel fuel is extremely flammable and engine. explosive under certain conditions. • NEVER jumpstart the engine. Sparks • Only fill the fuel tank with diesel fuel. caused by jumping the battery to the Filling the fuel tank with gasoline may starter terminals may cause a fire or...
  • Page 21 SAFETY DANGER DANGER FIRE AND EXPLOSION HAZARD! CRUSH HAZARD! • Diesel fuel is extremely flammable and explosive under certain conditions. • When you need to transport a generator for repair, have a helper • Before you operate the engine, check assist you when attaching it to a hoist for fuel leaks.
  • Page 22 SAFETY DANGER DANGER ELECTRIC SHOCK HAZARD! ELECTRIC SHOCK HAZARD! • NEVER handle live terminals or bare • ALWAYS have a licensed electrician wires. connect the generator to the utility circuit. • NEVER use the generator near standing water or snow. •...
  • Page 23 SAFETY DANGER DANGER ELECTRIC SHOCK / FIRE ELECTRIC SHOCK HAZARD! HAZARD! • The generator produces enough NEVER operate the generator if: electric power to cause a serious shock or electrocution if misused. • engine speed changes greatly. • NEVER use the generator in a location •...
  • Page 24 SAFETY WARNING WARNING SEVER HAZARD! • Keep hands and other body parts SLIP / TRIP HAZARD! away from moving / rotating parts Keep generator and nearby areas clean. such as the cooling fan and flywheel. • Keep the generator free of oil, mud •...
  • Page 25 SAFETY WARNING WARNING EXHAUST HAZARD! EXPOSURE HAZARD! • NEVER operate the engine in an enclosed area such as a garage, • Wear personal protective equipment tunnel, underground room, manhole or such as gloves, work shoes, eye and ship’s hold without proper ventilation. hearing protection as required by the task at hand.
  • Page 26 ALWAYS use a piece of wood other body parts and clothing away or cardboard. Have your authorized from moving / rotating parts. Yanmar industrial engine dealer or • Failure to comply could result in death distributor repair the damage. or serious injury.
  • Page 27 SAFETY WARNING WARNING 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. BURN HAZARD! Disconnect any tools and appliances • If you must drain the engine oil while it from the generator before starting.
  • Page 28 CAUTION CAUTION • Only use diesel fuels recommended by If you remove battery from generator, Yanmar for the best engine insulate the terminal on the end of the performance, to prevent engine red, positive (+) battery cable. If the damage and to comply with EPA / ARB terminal is not insulated, it may spark warranty requirements.
  • Page 29 SAFETY CAUTION CAUTION ALWAYS run the engine at full speed. Tips while starting engine with recoil NEVER run engine at lower speeds. At starter ( See “Starting Generator” on full speed, the engine runs at 3600 rpm page 72. ): under load.
  • Page 30 CAUTION extreme. • NEVER overfill the engine with engine • Contact your authorized Yanmar oil. industrial engine dealer or distributor • ALWAYS keep the oil level between the if you need to operate the engine at upper and lower lines on the oil high altitudes.
  • Page 31 • Failure to comply may impair the engine’s safety and performance characteristics and shorten the engine’s life. Any alterations to this engine may affect the warranty coverage of your engine. See “Yanmar Limited Warranty” on page v. 0000044enYDGOM YDG Operation Manual...
  • Page 32 Failure to follow these the warranty coverage on your engine. procedures may seriously harm the See “Yanmar Limited Warranty” on environment. page v. • Follow the guidelines of the EPA or Consult your authorized Yanmar...
  • Page 33 SAFETY CAUTION The maximum air intake restriction shall • L48V: 0.10 psi (0.69 kPa; 70 mm Aq) or less • L70V: 0.20 psi (1.37 kPa; 140 mm Aq) or less • L100V: 0.21 psi (1.47 kPa; 150 mm Aq) or less. Clean or replace the air cleaner element if the air intake restriction exceeds the above mentioned value.
  • Page 34 SAFETY This Page Intentionally Left Blank YDG Operation Manual...

  • Page 35: Product Overview

    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 has incorporated Exhaust Gas Recirculation (EGR) technology to meet the stringent exhaust emissions demands required by the Environmental Protection Agency (EPA - U.S.

  • Page 36: Component Identification

    PRODUCT OVERVIEW COMPONENT IDENTIFICATION YDG2700EV-6EH ‚k‚n‚v?@‚n‚h‚k?@‚v‚`‚q‚m‚h‚m‚f?@?I 0002408A Figure 1 1. Fuel Tank 6. Oil Drain Plug (one located on each side 2. Fuel Filler Cap of engine) 3. Engine Control Lever 7. Battery 4. Air Cleaner 8. Starter Motor 5. Oil Filler Cap / Dipstick 9.
  • Page 37 PRODUCT OVERVIEW YDG3700EV-6EI ‚v‚`‚q‚m‚h‚m‚f ‚k‚n‚v?@‚n‚h‚k?@‚v‚`‚q‚m‚h‚m‚f?@?I 0002409A Figure 2 1. Fuel Tank 6. Oil Drain Plug (one located on each side 2. Fuel Filler Cap of engine) 3. Engine Control Lever 7. Battery 4. Air Cleaner 8. Starter Motor 5. Oil Filler Cap / Dipstick 9.
  • Page 38 PRODUCT OVERVIEW YDG5500EV-6EI 0002410A Figure 3 1. Fuel Tank 6. Oil Drain Plug (one located on each side 2. Fuel Filler Cap of engine) 3. Engine Control Lever 7. Battery 4. Air Cleaner 8. Starter Motor 5. Oil Filler Cap / Dipstick 9.

  • Page 39: Location Of Labels

    Doing so may affect the warranty coverage on your engine. 1. Move engine speed lever to RUN. 2. Turn key to START and release. X3A15539K01 • See your authorized Yanmar industrial engine dealer or distributor for governor service. X3A15535K01 CAUTION...

  • Page 40: Safety Labels Ydg3700Ev-6Ei, Ydg5500Ev-6Ei

    Doing so may affect the warranty coverage on your engine. • Check for leakage from hoses and fittings and repair if necessary before starting engine. • See your authorized Yanmar industrial engine • Failure to comply will result in death or serious injury.

  • Page 41: Engine Label

    Refer to the specific EPA / ARB installation and maintenance (page 97) in the Periodic Maintenance Schedule section of this manual. Also refer to the Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only on page ix. 0002460A...

  • Page 42: Emission Control Labels

    PRODUCT OVERVIEW EMISSION CONTROL LABELS The 97/68/EC Directive Certified Engines Since emission control regulations are being issued on a global basis, it is necessary to identify which The engines described in this manual have been regulations a particular generator complies with. certified by the 97/68/EC Directive.

  • Page 43: Engine Family

    Engine Family designation: 5 YDX L 0.22 D Method of air aspiration Number of cylinders Combustion chamber design Displacement (liter) Non-road / Off-road engine Yanmar Diesel *2005 Model Year 5*: 2005 6 : 2006 7 : 2007 YDG Operation Manual...

  • Page 44: Function Of Major Components

    PRODUCT OVERVIEW FUNCTION OF MAJOR COMPONENTS Components Functions Air Cleaner The air cleaner prevents airborne contaminants from entering the engine. Periodic replacement of the air cleaner filter element is necessary. See the Periodic Maintenance Schedule on page 99 for the replacement frequency. Engine Dynamo A dynamo is located between the engine block and the flywheel.

  • Page 45: Generator Control Panel

    PRODUCT OVERVIEW GENERATOR CONTROL PANEL YDG2700EV-6EH ( 1 ) ( 2 ) ( 3 ) START STARTER ( 7 ) DC12V 8.3A BREAKER NEUTRAL BONDED ( 6 ) AC 120V 20.8A TOTAL TO FRAME BATTERY CHARGE ONLY ( 4 ) ( 5 ) 0002411A Figure 7...
  • Page 46 PRODUCT OVERVIEW YDG3700-6EV-6EI, YDG5500EV-6EI ( 1 ) ( 2 ) ( 3 ) ( 4 ) AC120V 41.6 A ( 10 ) AC120V/240V START ( 5 ) STARTER SW 240V 120V 20.8 A DC12V 8.3A ( 9 ) BREAKER BATTERY CHARGE ONLY NEUTRAL BONDED TO FRAME ( 8 ) ( 7 )

  • Page 47: Air Cooled Engine

    PRODUCT OVERVIEW AIR COOLED ENGINE The engine is air-cooled by means of 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.

  • Page 48: Engine Controls - Electric Starter

    Only hold the key in the START position for 15 seconds or the starter motor will CAUTION overheat. For maximum engine life, Yanmar 0000020en recommends that when shutting the engine down, you allow the engine to START (Figure 10, (3)) - Turn the key to this run, without load, for five minutes.

  • Page 49: Engine Control Lever

    If spark arrester reduces engine output and adjustment is ever required, contact increases fuel consumption. It also makes starting your authorized Yanmar industrial difficult. See Check Spark Arrester on page 56. engine dealer or distributor. 0000045en...
  • Page 50 PRODUCT OVERVIEW This Page Intentionally Left Blank YDG Operation Manual...

  • Page 51: Before You Operate

    • Fill the fuel tank. Store any containers and maintenance techniques. containing fuel in a well-ventilated • See your authorized Yanmar industrial area, away from any combustibles or engine dealer or distributor for sources of ignition.
  • Page 52 BEFORE YOU OPERATE DANGER DANGER FIRE AND EXPLOSION HAZARD! ELECTRIC SHOCK HAZARD! • Diesel fuel is extremely flammable and • NEVER handle live terminals or bare explosive under certain conditions. wires. • Be sure to place the diesel fuel • NEVER use the generator near container on the ground when standing water or snow.
  • Page 53 BEFORE YOU OPERATE DANGER DANGER ELECTRIC SHOCK HAZARD! ELECTRIC SHOCK HAZARD! • The generator produces enough • ALWAYS have a licensed electrician electric power to cause a serious connect the generator to the utility shock or electrocution if misused. circuit. •...
  • Page 54 BEFORE YOU OPERATE DANGER DANGER FIRE AND EXPLOSION HAZARD! ELECTRIC SHOCK / FIRE • Diesel fuel is extremely flammable and HAZARD! explosive under certain conditions. NEVER operate the generator if: • Before you operate the engine, check • engine speed changes greatly. for fuel leaks.
  • Page 55 • Failure to comply will result in death or hands. ALWAYS use a piece of wood serious injury. or cardboard. Have your authorized Yanmar industrial engine dealer or 0000003en distributor repair the damage. • Failure to comply could result in death DANGER or serious injury.
  • Page 56 BEFORE YOU OPERATE CAUTION WARNING • Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA / ARB warranty requirements. BURN HAZARD! • Only use clean diesel fuel. • If you must drain the engine oil while it •...
  • Page 57 BEFORE YOU OPERATE CAUTION CAUTION If you remove battery from generator, ALWAYS run the engine at full speed. insulate the terminal on the end of the NEVER run engine at lower speeds. At red, positive (+) battery cable. If the full speed, the engine runs at 3600 rpm terminal is not insulated, it may spark under load.

  • Page 58: Battery

    BEFORE YOU OPERATE BATTERY WARNING DANGER BURN HAZARD! • Batteries contain sulfuric acid. NEVER EXPLOSION HAZARD! allow battery fluid to come in contact with clothing, skin or eyes. Severe • Keep the area around the battery well- burns could result. ALWAYS wear ventilated.

  • Page 59: Activating The Battery

    BEFORE YOU OPERATE Activating the Battery 7. After letting battery stand, top off battery with electrolyte, if needed, so it is at the upper level Note: Do not remove the aluminum foil or line (Figure 2, (1)). Battery level should never sealing tape (Figure 1, (3)) from the be below the lower level line (Figure 2, (2)).

  • Page 60: Diesel Fuel

    BEFORE YOU OPERATE 0002493 Figure 4 DIESEL FUEL 0002492 Figure 3 Diesel Fuel Specifications 10. Install battery into generator. Diesel fuel should comply with the following 11. Reinstall battery hold-down (Figure 4, (1)) onto specifications. The table lists several worldwide battery.
  • Page 61 6. The use of bio-diesel fuels that do not comply with the standards as agreed to by the diesel Yanmar approves the use of bio-diesel fuels that do engine manufacturers and the diesel fuel not exceed a blend of 5% (by volume) of FAME with...

  • Page 62: Filling The Fuel Tank

    BEFORE YOU OPERATE Filling The Fuel Tank DANGER DANGER FIRE AND EXPLOSION HAZARD! • Diesel fuel is extremely flammable and FIRE AND EXPLOSION HAZARD! explosive under certain conditions. • Diesel fuel is extremely flammable and • Be sure to place the diesel fuel explosive under certain conditions.
  • Page 63 NEVER overfill the fuel • Only use diesel fuels recommended by tank. Yanmar for the best engine 4. Replace the fuel cap and hand-tighten. Over- performance, to prevent engine tightening the fuel cap will damage it.

  • Page 64: Engine Oil

    BEFORE YOU OPERATE ENGINE OIL • JASO (Japanese Automobile Standards Organization) The Yanmar YDG generators are equipped with a Notes: low oil pressure stop device. This device stops the engine automatically when the oil pressure falls 1. Be sure the engine oil, engine oil storage...

  • Page 65: Checking Engine Oil

    Engine Oil Capacity 1. Make sure engine is level. The following are the engine oil capacities for Yanmar YDG generators. 2. Remove oil cap / dipstick (Figure 7, (1)) from either location and wipe with clean cloth. Engine Oil Capacity 3.

  • Page 66: Generator Check

    BEFORE YOU OPERATE GENERATOR CHECK Recommended Minimum Wire Gauges (AWG) for Extension Cords AWG for Length of Cord DANGER Ampere ft (m) Load 50 (15) 100 (30) 150 (46) ELECTRIC SHOCK HAZARD! • ALWAYS have a licensed electrician connect the generator to the utility circuit.
  • Page 67 Different manufacturers of certain products may require more wattage. See your 600 watts x 3 = 1800 watts: Starting authorized Yanmar industrial engine dealer or Watts distributor with any questions. When figuring the generator load for...
  • Page 68 BEFORE YOU OPERATE (d) Add 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. Typical Electrical Appliance Wattages Application / Equipment Running / Rated Watts...
  • Page 69 BEFORE YOU OPERATE Figure 9, (1) shows the main switch on the WARNING YDG2700 generator. SUDDEN MOVEMENT HAZARD! ( 1 ) • 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.

  • Page 70: Dual Voltage Generators (Ydg3700 / 5500)

    BEFORE YOU OPERATE DUAL VOLTAGE GENERATORS (YDG3700 / 5500) Operation of Change-Over Switch Before starting the engine, place the change-over switch (Figure 11, (1) in the correct position for the rated voltage of the working instrument. ( 1 ) AC120V 41.6 A AC120V/240V START STARTER SW...

  • Page 71: Daily Checks

    DAILY CHECKS Visual Checks 1. Check for engine oil leaks. Before you begin any job, make sure the Yanmar YDG generator is in good operating condition. 2. Check for fuel leaks. Make sure you check the following items before you 3.

  • Page 72: Check Spark Arrester

    BEFORE YOU OPERATE Check Spark Arrester Check Battery Electrolyte Level Check the spark arrester for clogging and clean as necessary. DANGER WARNING If the engine has been running, the muffler and the spark arrester will be very hot. Allow these to cool before EXPLOSION HAZARD! proceeding.
  • Page 73 If operated at an angle • If the engine still will not start after charging, greater than 20° (in any direction) the have your authorized Yanmar industrial engine battery could leak fluid. Generator must dealer or distributor check the battery and the be on a flat level surface when checking engine’s starting system.

  • Page 74: Charging The Battery

    BEFORE YOU OPERATE Charging the Battery 1. Disconnect the battery cables from the battery. See Disconnecting and Connecting Battery Cables on page 59. DANGER 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.

  • Page 75: Disconnecting And Connecting Battery Cables

    BEFORE YOU OPERATE Disconnecting and Connecting WARNING Battery Cables DANGER BURN HAZARD! • Batteries contain sulfuric acid. NEVER allow battery fluid to come in contact with clothing, skin or eyes. Severe EXPLOSION HAZARD! burns could result. ALWAYS wear • Keep the area around the battery well- safety goggles and protective clothing ventilated.
  • Page 76 BEFORE YOU OPERATE 3. When connecting cables to battery connect the positive (+) cable (Figure 16, (1)) first. 4. Connect the negative (–) cable (Figure 16, (2)) to the battery last. 0002488 Figure 16 YDG Operation Manual...

  • Page 77: Generator Operation

    0000003en • Machine safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar industrial engine dealer or distributor for additional training. 0000002enGen YDG Operation Manual...
  • Page 78 GENERATOR OPERATION DANGER DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Only use the key switch to start the • Diesel fuel is extremely flammable and engine. explosive under certain conditions. • NEVER jumpstart the engine. Sparks • Only fill the fuel tank with diesel fuel. caused by jumping the battery to the Filling the fuel tank with gasoline may starter terminals may cause a fire or...
  • Page 79 GENERATOR OPERATION DANGER DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is extremely flammable and • Diesel fuel is extremely flammable and explosive under certain conditions. explosive under certain conditions. • Before you operate the engine, check •...
  • Page 80 GENERATOR OPERATION DANGER DANGER ELECTRIC SHOCK HAZARD! ELECTRIC SHOCK HAZARD! • NEVER handle live terminals or bare • ALWAYS have a licensed electrician wires. connect the generator to the utility circuit. • NEVER use the generator near standing water or snow. •...
  • Page 81 GENERATOR OPERATION DANGER DANGER ELECTRIC SHOCK / FIRE ELECTRIC SHOCK HAZARD! HAZARD! • The generator produces enough NEVER operate the generator if: electric power to cause a serious shock or electrocution if misused. • engine speed changes greatly. • NEVER use the generator in a location •...
  • Page 82 GENERATOR OPERATION WARNING WARNING SEVER HAZARD! • Keep hands and other body parts SLIP / TRIP HAZARD! away from moving / rotating parts Keep generator and nearby areas clean. such as the cooling fan and flywheel. • Keep the generator free of oil, mud •...
  • Page 83 GENERATOR OPERATION WARNING WARNING EXHAUST HAZARD! EXPOSURE HAZARD! • NEVER operate the engine in an enclosed area such as a garage, • Wear personal protective equipment tunnel, underground room, manhole or such as gloves, work shoes, eye and ship’s hold without proper ventilation. hearing protection as required by the task at hand.
  • Page 84 CAUTION • NEVER exceed the specified current limit for any one socket. For maximum engine life, Yanmar recommends that when shutting the 0000165en engine down, you allow the engine to run, without load, for five minutes. This...
  • Page 85 GENERATOR OPERATION CAUTION CAUTION NEVER hold the key in the START ALWAYS run the engine at full speed. position for longer than 15 seconds or NEVER run engine at lower speeds. At the starter motor will overheat. full speed, the engine runs at 3600 rpm 0000007en under load.
  • Page 86 Any alterations to this engine may affect the warranty 0000061enYDG coverage of your engine. See “Yanmar Limited Warranty” on page v. 0000044enYDGOM CAUTION The tightening torque in the “Standard Torque Chart” on page 98 should be applied only to the bolts with a “7”...
  • Page 87 60°F (15.6°C). operated in either temperature 0000003enGen extreme. • 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.

  • Page 88: Starting Generator

    GENERATOR OPERATION STARTING GENERATOR 4. Move the engine control lever (Figure 2, (1)) to the RUN position (Figure 2, (2)). Recoil Start ( 1 ) CAUTION ( 2 ) NEVER use an engine starting aid such as ether. Engine damage will result. 0000009en Use the following procedure to start the engine.

  • Page 89: Electric Start

    GENERATOR OPERATION 1. Grasp the recoil starter handle (Figure 3, (1)). Electric Start 2. Pull the handle out slowly until you feel strong resistance. CAUTION 3. Slowly return the recoil starter handle to the NEVER use an engine starting aid such initial position.

  • Page 90: Checking The Generator During Operation

    GENERATOR OPERATION CHECKING THE GENERATOR Start The Engine DURING OPERATION CAUTION NEVER use an engine starting aid such WARNING as ether. Engine damage will result. 0000009en Use the following procedure to start the engine using the electric start. BURN HAZARD! 1.

  • Page 91: Low Load Operation

    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.

  • Page 92: Shutting Down The Generator

    ( 2 ) ( 1 ) GENERATOR AC120V 41.6 A CAUTION AC120V/240V For maximum engine life, Yanmar recommends that when shutting the START engine down, you allow the engine to STARTER SW run, without load, for five minutes. This 240V 120V 20.8 A...

  • Page 93: Ac Application

    GENERATOR OPERATION AC APPLICATION Models YDG3700EV-6EI and YDG5500EV-6EI 1. Start the engine and make sure the voltage ( 1 ) ( 2 ) ( 3 ) meter (Figure 7, (1)) or (Figure 8, (4)) indicates the voltage. If it does not, the generator or voltage meter may be damaged.

  • Page 94: Dc Application

    GENERATOR OPERATION DC APPLICATION WARNING Note: DC terminals should be used for charging 12 Volt DC batteries only. Using the DC terminals for any other type of 12 volt appliance may cause damage to generator and appliance. BURN HAZARD! The DC terminal (Figure 7, (3)) or (Figure 8, (5)) may be used for charging 12 volt automotive-type •...
  • Page 95 (Figure 9, (2)) should pop out. If the RESET always connect the charging cables to button does not pop out, notify your Yanmar the battery first and then to the industrial engine dealer or distributor that generator.
  • Page 96 GENERATOR OPERATION This Page Intentionally Left Blank YDG Operation Manual...

  • Page 97: Periodic Maintenance

    0000003en • Machine safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar industrial engine dealer or distributor for additional training. 0000002enGen YDG Operation Manual...
  • Page 98 PERIODIC MAINTENANCE DANGER DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Diesel fuel is extremely flammable and • Diesel fuel is extremely flammable and explosive under certain conditions. explosive under certain conditions. • When you remove any fuel system •...
  • Page 99 PERIODIC MAINTENANCE DANGER DANGER FIRE AND EXPLOSION HAZARD! FIRE AND EXPLOSION HAZARD! • Only use the key switch to start the • Diesel fuel is extremely flammable and engine. explosive under certain conditions. • NEVER jumpstart the engine. Sparks • Only fill the fuel tank with diesel fuel. caused by jumping the battery to the Filling the fuel tank with gasoline may starter terminals may cause a fire or...
  • Page 100 PERIODIC MAINTENANCE DANGER DANGER FIRE AND EXPLOSION HAZARD! CRUSH HAZARD! • Diesel fuel is extremely flammable and explosive under certain conditions. • When you need to transport a generator for repair, have a helper • Before you operate the engine, check assist you when attaching it to a hoist for fuel leaks.
  • Page 101 PERIODIC MAINTENANCE DANGER DANGER ELECTRIC SHOCK HAZARD! ELECTRIC SHOCK HAZARD! • NEVER handle live terminals or bare • ALWAYS have a licensed electrician wires. connect the generator to the utility circuit. • NEVER use the generator near standing water or snow. •...
  • Page 102 PERIODIC MAINTENANCE DANGER DANGER ELECTRIC SHOCK / FIRE ELECTRIC SHOCK HAZARD! HAZARD! • The generator produces enough NEVER operate the generator if: electric power to cause a serious shock or electrocution if misused. • engine speed changes greatly. • NEVER use the generator in a location •...
  • Page 103 PERIODIC MAINTENANCE WARNING WARNING SEVER HAZARD! • Keep hands and other body parts SLIP / TRIP HAZARD! away from moving / rotating parts Keep generator and nearby areas clean. such as the cooling fan and flywheel. • Keep the generator free of oil, mud •...
  • Page 104 PERIODIC MAINTENANCE WARNING WARNING EXHAUST HAZARD! EXPOSURE HAZARD! • NEVER operate the engine in an enclosed area such as a garage, • Wear personal protective equipment tunnel, underground room, manhole or such as gloves, work shoes, eye and ship’s hold without proper ventilation. hearing protection as required by the task at hand.
  • Page 105 ALWAYS use a piece of wood other body parts and clothing away or cardboard. Have your authorized from moving / rotating parts. Yanmar industrial engine dealer or • Failure to comply could result in death distributor repair the damage. or serious injury.
  • Page 106 PERIODIC MAINTENANCE WARNING WARNING 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. BURN HAZARD! Disconnect any tools and appliances • If you must drain the engine oil while it from the generator before starting.
  • Page 107 CAUTION CAUTION • Only use diesel fuels recommended by If you remove battery from generator, Yanmar for the best engine insulate the terminal on the end of the performance, to prevent engine red, positive (+) battery cable. If the damage and to comply with EPA / ARB terminal is not insulated, it may spark warranty requirements.
  • Page 108 PERIODIC MAINTENANCE CAUTION CAUTION ALWAYS run the engine at full speed. Tips while starting engine with recoil NEVER run engine at lower speeds. At starter ( See “Starting Generator” on full speed, the engine runs at 3600 rpm page 72. ): under load.
  • Page 109 CAUTION extreme. • NEVER overfill the engine with engine • Contact your authorized Yanmar oil. industrial engine dealer or distributor • ALWAYS keep the oil level between the if you need to operate the engine at upper and lower lines on the oil high altitudes.
  • Page 110 20° (in any direction) or if an engine coverage of your engine. See “Yanmar runs for short periods of time (less than Limited Warranty” on page v.
  • Page 111 • L100V: 0.21 psi (1.47 kPa; 150 mm Aq) See “Yanmar Limited Warranty” on or less. page v. Clean or replace the air cleaner element...

  • Page 112: Precautions

    PERIODIC MAINTENANCE PRECAUTIONS CAUTION • Most electric appliances require more The Importance of Periodic than their rated wattage for start-up. Maintenance • NEVER exceed the specified current Engine deterioration and wear occurs in proportion limit for any one socket. to length of time the generator has been in service 0000164en and the conditions the generator is subject to during operation.

  • Page 113: The Importance Of Daily Checks

    “7” head. (JIS strength classification: 7T) Yanmar Replacement Parts Yanmar recommends that you use genuine Yanmar • Apply 60% torque to bolts parts when replacement parts are needed. that are not listed.

  • Page 114: Standard Torque Chart

    PERIODIC MAINTENANCE STANDARD TORQUE CHART Thread size × Pitch mm M6×1.0 M8×1.25 M10×1.5 M12×1.75 M14×1.5 M16×1.5 Tightening Torque in lbs 96.0 ± 9.0 ft lbs 19.0 ± 2.0 36.0 ± 4.0 65.0 ± 7.0 101.0 ± 7.0 167.0 ± 7.0 N·m 10.8 ±...

  • Page 115: Periodic Maintenance Schedule

    See “Yanmar Limited Warranty” on page v. Consult your authorized Yanmar industrial engine dealer or distributor for assistance when checking items marked...
  • Page 116 PERIODIC MAINTENANCE : Check : Replace : Contact your authorized Yanmar industrial engine dealer or distributor for these maintenance services. Periodic Maintenance Interval Every Every Every System Check Item Daily Every 50 Every 200 Every 400 1000 1500 2000 hours...

  • Page 117: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE WARNING PROCEDURES Daily, Before Operation Perform the following maintenance daily before BURN HAZARD! operation. • Batteries contain sulfuric acid. NEVER • Check Battery allow battery fluid to come in contact with clothing, skin or eyes. Severe •...
  • Page 118 • 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.
  • Page 119 Before you operate the engine check for any engine 0000013enYDG oil leaks. If you discover an engine oil leak see your authorized Yanmar industrial engine dealer or Before you operate the engine check the engine oil distributor to repair the engine.
  • Page 120 PERIODIC MAINTENANCE Check Spark Arrestor 2. Clean any carbon deposits from the spark arrester. 3. Reinstall the diffuser discs (Figure 2, (4)) and WARNING end cap (Figure 2, (3)) on the spark arrester (Figure 2, (1)) and secure with the locknut (Figure 2, (2)).
  • Page 121 • Failure to comply will result in death or serious injury. CAUTION 0000014en • Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA / ARB warranty requirements. • Only use clean diesel fuel.

  • Page 122: Daily, After Operation

    WARNING After you shut down the engine, check for any engine oil leaks. If you discover an engine oil leak, see your authorized Yanmar industrial engine dealer or distributor to repair the engine. BURN HAZARD! • Keep your hands and other body parts...

  • Page 123: After Initial 50 Hours Of Operation

    Before you operate the engine check for any fuel leaks. NEVER use your hands! If you discover a 0000011en fuel leak see your authorized Yanmar industrial engine dealer or distributor to repair the engine. YDG Operation Manual...
  • Page 124 PERIODIC MAINTENANCE The engine oil on a new engine becomes CAUTION 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. Be environmentally responsible.
  • Page 125 PERIODIC MAINTENANCE Clean / Inspect Engine Oil Filter (2) (1) Figure 5 0001123A Figure 4 10. Recheck the engine oil level by fully inserting, but not screwing in, the dipstick. Clean / inspect the engine oil filter as follows: 11. Add engine oil (Figure 5, (4)) as needed until 1.

  • Page 126: Every 50 Hours Of Operation

    PERIODIC MAINTENANCE Every 50 Hours of Operation ( 1 ) ( 2 ) Perform the following maintenance every 50 hours of operation. ( 3 ) • Clean Inlet Fuel Screen • Test GFCI Outlet Clean Inlet Fuel Screen DANGER 0002456A FIRE AND EXPLOSION HAZARD! Figure 6 •...

  • Page 127: Every 200 Hours Of Operation

    If the RESET button does not pop out, • Clean Air Cleaner Element notify your Yanmar industrial engine dealer or distributor. Do not use the generator until this • Replace Engine Oil and Clean / Inspect condition is fixed.
  • Page 128 PERIODIC MAINTENANCE 13. Reinstall the wing nut (Figure 8, (1)) and hand- The engine performance is adversely affected tighten. Overtightening the wing nut will when the air cleaner element is clogged with dust. damage the air cleaner assembly. Be sure to clean the air filter element periodically. Replace Engine Oil and Clean / 1.
  • Page 129 PERIODIC MAINTENANCE Drain the Fuel Tank and Replace CAUTION Outlet Fuel Filter DANGER Be environmentally responsible. Follow these procedures for hazardous waste disposal. Failure to follow these FIRE AND EXPLOSION HAZARD! procedures may seriously harm the • Diesel fuel is extremely flammable and environment.
  • Page 130 (Figure 9, (8)) to drain the fuel. 12. If any fuel leaks are found see your authorized 4. Inspect gasket and replace if damaged. Yanmar industrial engine dealer or distributor. 5. Loosen clamp (Figure 9, (2)) and disconnect fuel line (Figure 9, (3)).

  • Page 131: Every 400 Hours Of Operation

    • Check Commutator Brush and Slip Ring 1000 hours to obtain optimum engine performance. Replace Air Cleaner Element See your authorized Yanmar industrial engine dealer or distributor for this service. Replace the air cleaner element every 400 hours even if it is not damaged or dirty. See Clean Air Cleaner Element on page 111.

  • Page 132: Every 1500 Hours Of Operation

    Regularly check the fuel system hoses. If they are cracked or degraded, replace them. Replace the hoses at least every two years, or 2000 hours, WARNING whichever occurs first. See your authorized Yanmar industrial engine dealer or distributor to replace fuel system hoses. CAUTION HIGH-PRESSURE HAZARD! •...

  • Page 133: Troubleshooting

    If any indicator illuminates during the key switch is in the ON position, see engine operation, stop the engine your authorized Yanmar industrial immediately. Determine the cause and engine dealer or distributor for service repair the problem before you continue before operating the engine.

  • Page 134: Troubleshooting Chart

    • Replace fuel filter Drain the Fuel Tank and Replace Outlet Fuel Filter on page 113 • Poor fuel injection • See authorized Yanmar — industrial engine dealer or • Compressed air leakage from — distributor intake / exhaust valves •...
  • Page 135 • Improper diesel fuel • Replace with recommended Diesel Fuel diesel fuel Specifications on page 44 • Faulty spray pattern of fuel • See authorized Yanmar — injection industrial engine dealer or distributor • Fuel injection timing delay — • Engine burning oil —...

  • Page 136: Troubleshooting Information

    INFORMATION If your generator does not operate properly, refer to the troubleshooting chart or see your authorized Yanmar industrial engine dealer or distributor. Supply the authorized Yanmar industrial engine dealer or distributor with the following information: • Model name and serial number of your...

  • Page 137: Electrical Wiring Diagram

    TROUBLESHOOTING ELECTRICAL WIRING DIAGRAM YDG2700EV-6EH ‚w ‚v 0002449 Figure 3 YDG Operation Manual...
  • Page 138 TROUBLESHOOTING YDG3700EV-6EI YDG5500EV-6EI ‚w ‚v 0002450 Figure 4 YDG Operation Manual...

  • Page 139: Long Term Storage

    LONG TERM STORAGE YDG Operation Manual INTRODUCTION BEFORE YOU PLACE THE GENERATOR IN LONG TERM This section of the Operation Manual describes the procedures necessary to place the generator into STORAGE long term storage (three months or longer) and how to place it back into operation.
  • Page 140 LONG TERM STORAGE CAUTION WARNING Protect the air cleaner and electric components from damage when you use steam or use high-pressure water to clean the engine. 0000014en2V BURN HAZARD! • Batteries contain sulfuric acid. NEVER 1. Perform the next Preventive Maintenance allow battery fluid to come in contact procedure.

  • Page 141: Returning The Engine To Service

    LONG TERM STORAGE RETURNING THE ENGINE TO SERVICE 1. Perform the Daily Checks on page 55. 2. Start the engine. Allow the engine to run without load for approximately 5 to 10 minutes while you check for: (a) abnormal noises or vibration (b) fuel and engine oil leaks.
  • Page 142 LONG TERM STORAGE This Page Intentionally Left Blank YDG Operation Manual...

  • Page 143: Specifications

    SPECIFICATIONS YDG Operation Manual PRINCIPAL SPECIFICATIONS Generator Model YDG2700EV-6EH YDG3700EV-6EI YDG5500EV-6EI Type Revolving field type single-phase alternating current generator Frequency 60 Hz Output Max. 2.7 kW 3.7 kW 5.5 kW Rated 2.5 kW 3.5 kW 5.0 kW V-A (W) 12V - 8.3A (100) Voltage 120V 120V, 240V...
  • Page 144 SPECIFICATIONS Model YDG2700EV-6EH YDG3700EV-6EI YDG5500EV-6EI Generator Size in (mm) 25.6 x 16.4 x 19.7 25.6 x 19.5 x 20.9 28.3 x 18.9 x 22.8 L x W x H (649 x 416 x 500) (650 x 496 x 530) (720 x 480 x 578) Dry Weight lb (kg) 141 (64)

  • Page 145: Engine

    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 •...
  • Page 146 SPECIFICATIONS This Page Intentionally Left Blank YDG Operation Manual...

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