Yanmar YDG Series User manual

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

ii YDG Operation Manual
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.
© 2005 Yanmar Co. Ltd.

YDG Operation Manual iii
INTRODUCTION
YDG Operation Manual
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.

INTRODUCTION
iv YDG Operation Manual
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 v
YANMAR
WARRANTIES
YDG Operation Manual
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.

YANMAR WARRANTIES
vi YDG Operation Manual
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
Corp., LTD. website at:
http://www.yanmar.co.jp (The Japanese language page will be displayed.) For English language “click” on
“English Page.”)
• “Click” on “Network” in the website heading to view the “Yanmar Worldwide Network.”
• Choose and “Click” on the desired product group.
• “Click” on the Icon closest to your region.
• “Click” on the desired country or Associate company to locate your nearest authorized Yanmar industrial
engine dealer or distributor.
• You may also contact Yanmar by clicking on “Inquiry” 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.

YANMAR WARRANTIES
YDG Operation Manual vii
Yanmar Limited Warranty - Continued
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.

YANMAR WARRANTIES
viii YDG Operation Manual
Yanmar Limited Warranty - Continued
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.
Retail Purchaser Registration

YANMAR WARRANTIES
YDG Operation Manual ix
EMISSION SYSTEM WARRANTY
YANMAR CO., LTD. LIMITED EMISSION CONTROL SYSTEM
WARRANTY - USA ONLY
Your Warranty Rights and Obligations:
California
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. In
all states, 1998 and later non-road compression-ignition engines must be designed, built and equipped to
meet the United States EPA emissions standards. Yanmar warrants the emission control system on your
engine for the periods of time listed below provided there has been no abuse, neglect or improper
maintenance of your engine.
Your emission control system may include parts such as the fuel injection system and the air induction
system. Also included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, Yanmar will repair your non-road compression-ignition engine at no
charge to you including diagnosis, parts and labor.
Manufacturer’s Warranty Period:
The model year 1998 or later certified and labeled non-road compression-ignition engines are warranted
for the periods listed below. If any emission-related part on your engine is found to be defective during the
applicable warranty period, the part will be replaced by Yanmar.
Engine Type Warranty Period by Number of Years or Hours of Operation
Constant speed engines rated at or above
50 hp SAE (37 kW)
The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of five (5) years.
Constant speed engines rated under 50 hp
SAE (37 kW) with rated speeds greater than
or equal to 3,000 rpm
The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of two (2) years.
Engines rated at or above 26 hp SAE
(19 kW)
The warranty period is five (5) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of five (5) years.
Engines rated under 26 hp SAE (19 kW)
The warranty period is two (2) years or 3,000 hours of use, whichever occurs first.
In the absence of a device to measure the hours of use, the engine has a
warranty period of two (2) years.

YANMAR WARRANTIES
xYDG Operation Manual
Limited Emission Control System Warranty - USA Only - Continued
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. Warranted parts scheduled for replacement as required maintenance in
the operation manual are warranted for the period of time prior to the first scheduled replacement. Any part
repaired or replaced under warranty shall be warranted for the remaining warranty period.
During the warranty period, Yanmar is liable for damages to other engine components caused by the failure
of any warranted part during the warranty period.
Any replacement part which is functionally identical to the original equipment part in all respects may be
used in the maintenance or repair of your engine, and shall not reduce Yanmar’s warranty obligations. Add-
on or modified parts that are not exempted may not be used. The use of any non-exempted add-on or
modified parts shall be grounds for disallowing a warranty.
Warranted Parts:
This warranty covers engine components that are a part of the emission control system of the engine as
delivered by Yanmar to the original retail purchaser. Such components may include the following:
• Fuel Injection System
• Cold Start Enrichment System
• Intake Manifold
• Turbocharger Systems
• Exhaust Manifold
• Positive Crankcase Ventilation System
• Hoses, belts, connectors and assemblies associated with emission control systems
Since emissions related parts may vary slightly between models, certain models may not contain all of
these parts and other models may contain the functional equivalents.

YANMAR WARRANTIES
YDG Operation Manual xi
Limited Emission Control System Warranty - USA Only - Continued
Exclusions:
Failures other than those arising from defects in material and / or workmanship are not covered by this
warranty. The warranty does not extend to the following: malfunctions caused by abuse, misuse, improper
adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance or use
of non-recommended fuels and lubricating oils; accident-caused damage, and replacement of expendable
items made in connection with scheduled maintenance. Yanmar disclaims any responsibility for incidental
or consequential damages such as loss of time, inconvenience, loss of use of equipment / engine or
commercial loss.
Owner’s Warranty Responsibilities:
As the engine owner, you are responsible for the performance of the required maintenance listed in
your owner’s manual. Yanmar recommends that you retain all documentation, including receipts, covering
maintenance on your non-road compression-ignition engine, but Yanmar cannot deny warranty solely for
the lack of receipts, or for your failure to ensure the performance of all scheduled maintenance.
Yanmar may deny your warranty coverage of your non-road compression-ignition engine if a part has failed
due to abuse, neglect, improper maintenance or unapproved modifications.
Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no
longer operating in compliance with applicable emissions requirements.
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. If you have any questions regarding your warranty rights and responsibilities, or would like
information on the nearest Yanmar dealer or authorized service center, you should contact Yanmar
America Corporation at 1-800-872-2867.

YANMAR WARRANTIES
xii YDG Operation Manual
This Page Intentionally Left Blank

YDG Operation Manual xiii
TABLE OF
CONTENTS
YDG Operation Manual
Page
Introduction ............................................................................................ iii
Record of Ownership.......................................................................... iv
Yanmar Warranties.................................................................................. v
Yanmar Limited Warranty.................................................................... v
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? ...................................... vii
Warranty Limitations:................................................................... vii
Warranty Modifications:............................................................... vii
Questions: ................................................................................... vii
Retail Purchaser Registration..................................................... viii
Emission System Warranty ................................................................ ix
Yanmar Co., Ltd. Limited Emission Control System
Warranty - USA Only.......................................................................... ix
Your Warranty Rights and Obligations: ........................................ ix
Manufacturer’s Warranty Period:.................................................. ix
Warranty Coverage: ...................................................................... x
Warranted Parts: ........................................................................... x
Exclusions: ................................................................................... xi
Owner’s Warranty Responsibilities:.............................................. xi
Table of Contents................................................................................. xiii
Safety........................................................................................................ 1
Safety Statements ............................................................................... 1
Safety Precautions .............................................................................. 2

TABLE OF CONTENTS
xiv YDG Operation Manual
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 ............................................................................... 25
EPA / ARB Emission Control Regulations - USA Only...................... 25
Emission Control Labels ................................................................... 26
EPA / ARB Labels ....................................................................... 26
The 97/68/EC Directive Certified Engines................................... 26
Engine Family ................................................................................... 27
Function of Major Components ......................................................... 28
Generator Control Panel ................................................................... 29
Air Cooled Engine ............................................................................. 31
Engine Controls – Recoil Starter....................................................... 31
Recoil Starter............................................................................... 31
Decompression Lever ................................................................. 31
Engine Controls – Electric Starter ..................................................... 32
Key Switch................................................................................... 32
Engine Control Lever................................................................... 33
Spark Arrester ............................................................................. 33
Before You Operate .............................................................................. 35
Battery............................................................................................... 42
Activating the Battery .................................................................. 43
Diesel Fuel ........................................................................................ 44
Diesel Fuel Specifications ........................................................... 44
Filling The Fuel Tank................................................................... 46
Engine Oil.......................................................................................... 48
Engine Oil Specifications............................................................. 48
Engine Oil Viscosity..................................................................... 48
Checking Engine Oil.................................................................... 49
Adding Engine Oil........................................................................ 49
Engine Oil Capacity..................................................................... 49
Generator Check............................................................................... 50
Dual Voltage Generators (YDG3700 / 5500) .................................... 54
Operation of Change-Over Switch .............................................. 54
Daily Checks ..................................................................................... 55
Visual Checks.............................................................................. 55

TABLE OF CONTENTS
YDG Operation Manual xv
Check Diesel Fuel and Engine Oil Levels ................................... 55
Check Battery.............................................................................. 55
Check Spark Arrester .................................................................. 56
Check Battery Electrolyte Level................................................... 56
Charging the Battery.................................................................... 58
Disconnecting and Connecting Battery Cables ........................... 59
Generator Operation ............................................................................. 61
Starting Generator............................................................................. 72
Recoil Start.................................................................................. 72
Electric Start ................................................................................ 73
Checking the Generator During Operation........................................ 74
Low Load Operation .................................................................... 75
Shutting Down the Generator............................................................ 76
AC Application................................................................................... 77
DC Application................................................................................... 78
Periodic Maintenance ........................................................................... 81
Precautions ....................................................................................... 96
The Importance of Periodic Maintenance.................................... 96
Performing Periodic Maintenance ............................................... 96
The Importance of Daily Checks ................................................. 97
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................................................................... 97
Standard Torque Chart...................................................................... 98
Periodic Maintenance Schedule........................................................ 99
Periodic Maintenance Procedures .................................................. 101
Daily, Before Operation ............................................................. 101
Daily, After Operation ................................................................ 106
After Initial 50 Hours of Operation ............................................. 107
Every 50 Hours of Operation..................................................... 110
Every 200 Hours of Operation................................................... 111
Every 400 Hours of Operation................................................... 115
Every 1000 Hours of Operation................................................. 115
Every 1500 Hours of Operation................................................. 116
Every 2000 Hours of Operation................................................. 116
Troubleshooting.................................................................................. 117
Troubleshooting Chart..................................................................... 118
Troubleshooting Information............................................................ 120

TABLE OF CONTENTS
xvi YDG Operation Manual
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 .................................................................................. 127
Engine ....................................................................................... 129

YDG Operation Manual 1
SAFETY
YDG Operation Manual
SAFETY STATEMENTS
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 labels. Keep the labels 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 label attached to it, make sure you order
the new part and label 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.
ADANGER
Danger (the word “DANGER” is in white
letters with a red rectangle behind it) –
indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury. Danger
is limited to the most extreme
situations.
0000001en
A
AWARNING
Warning (the word “WARNING” is in
black letters with an orange rectangle
behind it) – indicates a potentially
hazardous situation which, if not
avoided, could result in death or serious
injury.
0000001en
ACAUTION
Caution (the word “CAUTION” is in black
letters with a yellow rectangle behind it)
– indicates a potentially hazardous
situation which, if not avoided, may
result in minor or moderate injury.
0000001en
CAUTION
Caution without the safety alert symbol
indicates a potentially hazardous
situation that can cause damage to the
machine, personal property and / or the
environment or cause the machine to
operate improperly.
0000001en

SAFETY
2YDG Operation Manual
SAFETY PRECAUTIONS
Before You Operate
During Operation and Maintenance
CAUTION
NEVER permit anyone to operate the
generator without proper training.
• Read and understand this Operation
Manual before you operate or service
the generator to ensure that you follow
safe operating practices and
maintenance procedures.
• 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
ADANGER
EXPLOSION HAZARD!
• Keep the area around the battery well-
ventilated. While the engine is running
or the battery is charging, hydrogen
gas is produced which can be easily
ignited.
• Keep sparks, open flame and any other
form of ignition away while the engine
is running or battery is charging.
• Failure to comply will result in death or
serious injury.
0000003en

SAFETY
YDG Operation Manual 3
ADANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• When you remove any fuel system
component to perform maintenance
(such as changing the fuel filter) place
an approved container under the
opening to catch the fuel.
• NEVER use a shop rag to catch the
fuel. Vapors from the rag are extremely
flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system
is under pressure and fuel could spray
out when you remove any fuel system
component.
• Failure to comply will result in death or
serious injury.
0000009en
ADANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• NEVER use diesel fuel as a cleaning
agent.
• Failure to comply will result in death or
serious injury.
0000012en
ADANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• NEVER remove the fuel cap with the
engine running.
• Failure to comply will result in death or
serious injury.
0000011en
ADANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• Be sure to 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.
• NEVER place diesel fuel or other
flammable material such as oil, hay or
dried grass close to the engine during
engine operation or shortly after
shutdown.
• Failure to comply will result in death or
serious injury.
0000014en

SAFETY
4YDG Operation Manual
0
0
ADANGER
FIRE AND EXPLOSION HAZARD!
• Only use the key switch to start the
engine.
• NEVER jumpstart the engine. Sparks
caused by jumping the battery to the
starter terminals may cause a fire or
explosion.
• Failure to comply will result in death or
serious injury.
0000004en
ADANGER
FIRE AND EXPLOSION HAZARD!
• Diesel fuel is extremely flammable and
explosive under certain conditions.
• 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.
• Wipe up all spills immediately.
• Keep sparks, open flames or any other
form of ignition (match, cigarette,
static electric source) away when
fueling / refueling.
• NEVER overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated
area, away from any combustibles or
sources of ignition.
• Failure to comply will result in death or
serious injury.
0000005en