YANMAR Operation Manual YDG Series

OPERATION
MANUAL
DIESEL POWERED GENERATORS
YDG series
YDG3700N-6BYI2 YDG3700N-6EBYI2
YDG3700V-5BYI2 YDG3700V-5EBYI2
YDG5500N-6BYI2 YDG5500N-6EBYI2
YDG5500V-5BYI2 YDG5500V-5EBYI2
en original instructions
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest
information available at the time of publishing. The illustrations used in this manual are
intended as representative reference views only. Moreover, because of our continuous
product improvement policy, we may modify information, illustrations and/or specifications
to explain and/or exemplify a product, service or maintenance improvement. We reserve
the right to make any change at any time without notice. YANMAR is a registered trade-
mark of YANMAR POWER TECHNOLOGY CO., LTD. in Japan, the United States and/or
other countries.
All Rights Reserved:

No part of this publication may be reproduced or used in any form by any means - graph-
ic, electronic, or mechanical, including photocopying, recording, taping, or information
storage and retrieval systems - without the written permission of YANMAR POWER
TECHNOLOGY CO., LTD.
In case of exporting this product and providing the related technical material to non-resi-
dents in Japan or residents in overseas, it is required to comply with the export and trade
control laws and regulations of Japan and other relevant countries. Please be careful to
proceed with necessary procedure.
MODEL YDG3700V-5EBYI2, YDG3700V-5BYI2, YDG5500V-5EBYI2, YDG5500V-5BYI2

OPERATION MANUAL YDG3700N-6EBYI2, YDG3700N-6BYI2, YDG5500N-6EBYI2, YDG5500N-6 BYI2
CODE YIYDG-EN0000
All Rights Reserved, Copyright YANMAR ITALY S.p.A.

YANMAR
YDG Operation Manual
WARRANTIES
YANMAR LIMITED WARRANTY
What is Covered by this Warranty?
YANMAR warrants to the original retail purchaser that a new YANMAR YDG diesel generator will be free
from defects in material and/or workmanship for the duration of the warranty period.
This warranty is provided in lieu of all other warranties, express or implied. YANMAR specifically disclaims
any implied warranties of merchantability or fitness for a particular purpose, except where such disclaimer
is prohibited by law. If such disclaimer is prohibited by law, then implied warranties shall be limited in
duration to the life of the express warranty.
How Long is the Warranty Period?

The YANMAR standard limited warranty period begins on the date of the delivery of the new YANMAR YDG
diesel generator to the first retail purchaser and extends for a period of twenty-four (24) months or
two-thousand (2000) engine operation hours, whichever occurs first. The warranty period (by duration
or operation hours) begins on the date of delivery to the original retail purchaser and is valid only until the
applicable warranted duration has passed or the operation hours are exceeded, whichever comes first.
YDG Operation Manual i

YANMAR WARRANTIES
YANMAR limited warranty - continued
What the Generator Owner must Do:

If you believe your YANMAR generator has experienced a failure due to a defect in material and/or
workmanship, you must contact an authorized YANMAR industrial engine dealer or distributor within thirty
(30) days of discovering the failure. You must provide proof of ownership of the generator, proof of the date
of the generator purchase and delivery, and documentation of the generator operation hours. Acceptable
forms of proof of delivery date include, but are not limited to: the original warranty registration or sales
receipts or other documents maintained in the ordinary course of business by YANMAR dealers and/or
distributors, indicating the date of delivery of the YANMAR product to the original retail purchaser. This
information is necessary to establish whether the YANMAR product is still within the warranty period. Thus,
YANMAR strongly recommends you register your generator as soon as possible after purchase in order to
facilitate any future warranty matters.
You are responsible for the transportation of the generator to and from the repair location as designated by
YANMAR.
To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor:

You can locate your nearest authorized YANMAR industrial engine dealer or distributor by visiting the
YANMAR CO., LTD. website at:
http://www.yanmar.co.jp (The Japanese language page will be displayed.) For English language “click” on
“Global” icon.
• “Click” on “Dealer Locator” in the website heading to view the “Dealer Locator” menu.
• Choose the Country from the pull down menu.
• Choose the Product Category from the pull down menu.
• “Click” on “Search” to browse YANMAR dealer or distributor.
• You may also contact YANMAR by clicking on “Contact” icon in the website heading and typing in your
question or comment.
What YANMAR will Do:

YANMAR warrants to the original retail purchaser of a new YANMAR generator that YANMAR will make
such repairs and/or replacements at YANMAR’s option, of any part(s) of the YANMAR product covered by
this warranty found to be defective in material and/or workmanship. Such repairs and/or replacements will
be made at a location designated by YANMAR at no cost to the purchaser for parts or labor.
ii YDG Operation Manual

YANMAR WARRANTIES
34127
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.
YDG Operation Manual iii

YANMAR WARRANTIES
Retail Purchaser Registration
It is very important for the original retail purchaser to register the YANMAR product. Registration
enables YANMAR to provide the best support for your YANMAR YDG diesel generator.
At the time of purchase, YANMAR highly recommends registering the retail purchaser’s information through
website http://www.yanmar.co.jp as soon as possible.
If it is not possible to access the website, please contact the nearest authorized YANMAR industrial engine
dealer or distributor.
iv YDG Operation Manual

[ F I "Qr gtcvkqp"Ocpwcn
INTRODUCTION
Welcome to the world of YANMAR! • Constant efforts are made to improve the quality
YANMAR has been the leader in industrial diesel and performance of YANMAR products, so some
engines for over 90 years. We developed the details included in this Operation Manual may
world’s first practical small-sized diesel engine in differ slightly from your generator. If you have any
1933. Our engineers are continuously developing questions about these differences, please contact
new technology to keep YANMAR on the your authorized YANMAR industrial engine dealer
leading-edge of the industry. The diesel-powered or distributor.
generator is only one example of the new • When exporting or providing this product and
technology we have developed. We are committed manual to non-residents, please comply with the
to maintaining our environment, and are proud of security trade control laws and regulations of
our history of innovation, quality and respect for Japan and other relevant countries.
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.
YDG Operation Manual v

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:________________________________________________________________________
vi YDG Operation Manual

INTRODUCTION
34127
EC DECLARATION OF CONFORMITY
According with Machinery Directive 2006/42/CE, Annex II.1.A
Manufacturer: YANMAR ITALY s.p.a.

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:
- Machinery Directive 2006/42/CE
- Low Voltage Directive 2014/35/UE
- Electromagnetic Compatibility (EMC) Directive 2014/30/UE
- RoHS 2011/65/UE
And with the following harmonised standards:
Machinery: EN 12100, UNI EN ISO 8528-1, UNI EN ISO 8528-13

Low Voltage: EN 60204-1
Electromagnetic Compatibility: EN 55012:2007, EN 61000-6-1:2019
The manufacturer of the machinery, take the responsibilty to transmit, in response to a motivated request of the
National Authorities, informations regarding the machinery related to this declaration.
Name and address of the pearson authorized to compile and

Pearson empowered to draw up the declaration
keep the technical documentation :
Ing. Carlo Cavallero

___________________________ Ing. Carlo Cavallero
_______________________________
President (----------------) President (----------------)
YDG Operation Manual vii

INTRODUCTION
This Page Intentionally Left Blank
viii YDG Operation Manual

TABLE OF
CONTENTS
[ F I "Qr gtcvkqp"Ocpwcn Page
YANMAR Warranties ................................................................................ i
YANMAR Limited Warranty.................................................................. i
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? ....................................... iii
Warranty Limitations: ................................................................... iii
Warranty Modifications: ............................................................... iii
Questions: .................................................................................... iii
Introduction ............................................................................................. v
Record of Ownership.......................................................................... vi
EC Declaration of Conformity..............................................................vii
Table of Contents ................................................................................... ix
YDG Operation Manual ix

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 .............................. 15
Generator Decal .......................................................................... 16
Engine Nameplate (Typical) ........................................................ 16
Function of Major Components ......................................................... 17
Generator Control Panel ................................................................... 18
Air Cooled Engine ............................................................................. 20
Engine Controls - Recoil Starter........................................................ 20
Recoil Starter............................................................................... 20
Decompression Lever ................................................................. 20
Engine Controls - Electric Starter ...................................................... 21
Key Switch................................................................................... 21
Engine Speed Control Lever ....................................................... 21
Before You Operate .............................................................................. 23
Introduction ....................................................................................... 23
Battery ............................................................................................... 24
Checking Battery Electrolyte Level.............................................. 24
Charging the Battery ................................................................... 25
Disconnecting and Connecting Battery Cables ........................... 25
Diesel Fuel ........................................................................................ 26
Diesel Fuel Specifications ........................................................... 26
Filling the Fuel Tank .................................................................... 28
Engine Oil.......................................................................................... 28
Engine Oil Specifications ............................................................ 28
Engine Oil Viscosity..................................................................... 29
Checking Engine Oil.................................................................... 29
Adding Engine Oil........................................................................ 30
Engine Oil Capacity..................................................................... 30
Generator Check ............................................................................... 30
Selecting the Proper Load........................................................... 32
Initial Engine Start Up ....................................................................... 34
x YDG Operation Manual

TABLE OF CONTENTS
34127
Daily Checks ..................................................................................... 34

Visual Checks.............................................................................. 34
Check Battery Electrolyte Level................................................... 34
Check Diesel Fuel and Engine Oil Levels ................................... 34
Generator Operation ............................................................................. 35
Introduction........................................................................................ 35
Starting the Generator....................................................................... 36
Recoil Start .................................................................................. 36
Electric Start ................................................................................ 37
Checking the Generator Set During Operation ................................. 38
Low Load Operation .................................................................... 39
Shutting Down the Generator............................................................ 39
AC Application................................................................................... 40
DC Application................................................................................... 41
Periodic Maintenance ........................................................................... 43
Introduction........................................................................................ 43
Precautions ....................................................................................... 44
The Importance of Periodic Maintenance.................................... 44
Performing Periodic Maintenance ............................................... 44
The Importance of Daily Checks ................................................. 44
Keep a Log of Generator Hours and Daily Checks ..................... 44
YANMAR Replacement Parts...................................................... 44
Tools Required ............................................................................ 44
Ask Your Authorized YANMAR Industrial Engine Dealer or
Distributor for Help....................................................................... 44
Tightening Fasteners................................................................... 45
Tightening Torques for Standard Bolts and Nuts .............................. 46
Periodic Maintenance Schedule........................................................ 47
Periodic Maintenance Procedures .................................................... 49
Dismantling ....................................................................................... 60
Troubleshooting .................................................................................... 61
Troubleshooting Information.............................................................. 61
Troubleshooting Chart....................................................................... 62
Electrical Wiring Diagram .................................................................. 64
Electrical Equipment Connection........................................................66
Long-Term Storage ............................................................................... 69
Introduction........................................................................................ 69
Before You Place the Generator in Long-Term Storage ................... 70
Returning the Engine to Service........................................................ 70
Specifications ........................................................................................ 71
Principal Specifications ..................................................................... 71
YDG Operation Manual xi

TABLE OF CONTENTS
xii YDG Operation Manual

SAFETY
YANMAR considers safety of great importance and
recommends that anyone that comes into close CAUTION
contact with its products, such as those that install, Indicates a hazardous situation which, if not
operate, maintain or service YANMAR products, avoided, could result in minor or moderate
exercise care, common sense and comply with the injury.
safety information in this manual and on the
machine’s safety decals. Keep the decals from NOTICE
becoming dirty or torn and replace them if they are
lost or damaged. Also, if you need to replace a part Indicates a situation which can cause damage to
that has a decal attached to it, make sure you order the machine, personal property and/or the
the new part and decal at the same time. environment or cause the equipment to operate
improperly.
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.
DANGER
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
YDG Operation Manual 1

SAFETY
SAFETY PRECAUTIONS DANGER

There is no substitute for common sense and Explosion Hazard
careful practices. Improper practices or
• Always place the diesel fuel
carelessness can cause burns, cuts, mutilation,
container on the ground when
asphyxiation, other bodily injury or death. This
transferring the diesel fuel from
information contains general safety precautions
the pump to the container. Hold
and guidelines that must be followed to reduce risk
the hose nozzle firmly against the
to personal safety. Special safety precautions are
side of the container while filling
listed in specific procedures. Read and understand
it. This prevents static electricity
all of the safety precautions before operation or
buildup which could cause sparks
performing repairs or maintenance.
and ignite fuel vapors.
DANGER • Diesel fuel is flammable and explosive under
certain conditions. Always store any
Be assured no children or animals are in the containers containing fuel in a well-ventilated
surrounding zone of generator set during area, away from any combustibles or sources
operation and handling. of ignition. Wipe up all spills immediately and
never use a shop rag to catch spilled fuel.
DANGER • Before you operate the engine, check for fuel
• Never permit anyone to install or leaks.
operate the generator set without • Avoid serious personal injury. Never
proper training. jump-start the engine. Sparks caused by
shorting the battery to the starter terminals
may cause a fire or explosion. Only use the
• Read and understand this Operation Manual key switch to start the engine.
before you operate or service the generator • Avoid serious personal injury or equipment
set to ensure that you follow safe operating damage. While the engine is running or the
practices and maintenance procedures. battery is charging, hydrogen gas is being
• Safety signs and decals are additional produced and can be easily ignited. Always
reminders for safe operating and keep the area around the battery
maintenance techniques. well-ventilated and keep sparks, open flames
and any other form of ignition out of the area.
• See your authorized YANMAR dealer or
distributor for additional training. • Never place diesel fuel, flammable material
such as oil, hay or dried grass or chemical
Exhaust Hazard gases or fumes close to the engine during
engine operation or shortly after shut down.
•Never operate the generator in
an enclosed area. Operating a • Never use metal pipe that carries combustible
generator indoors can kill you in materials or gases to ground the generator.
minutes. Generator exhaust • Never operate the generator in explosion risk
contains carbon monoxide. This ambients
is a poison you cannot see or
smell. Only operate the generator
outside and far away from
windows, doors and vents.
2 YDG Operation Manual

SAFETY
34127
connected to the sockets of the gen-set,

DANGER unless double insulated ones (class II), must
Electric Shock Hazard be equipped with PE conductor in order to
• Always have a licensed ensure equipotential bonding between the
electrician connect the generator conductive structural parts of gen-set and the
to the utility circuit. The generator appliances.
must not be connected to other • If using electrical separation protection
power sources.Improper method for indirect contact, the GENSET
installation can cause the must be physically disconnected from the
generator to back-feed into the ground (refer to page 66 scheme).
utility power line. This may
• It is therefore IMPORTANT that you ONLY use
electrocute a power company line
the generator to supply equipment in the
repair person.
following combinations.
• Never use if the generator is wet or damp.
• One or more of ‘‘CLASS II‘‘ equipment
• Never use the generator in a location exposed
• Only ONE item of ‘‘CLASS I‘‘ equipment
to rain, snow, water spray or standing water. If
the generator must be used outside, protect it • One or more of ‘‘CLASS II‘‘ equipment and
from the weather. Moisture or ice can cause a only ONE item of ‘‘CLASS I‘‘ equipment.
malfunction or short circuit in the electrical • At page 66 are shown different cases of load
components which could result in connections. All not mentioned connection
electrocution. schemes are NOT allowed.
• Never operate the generator in rain or a • Protection by means of ELECTRICAL
floodplain unless proper precautions are SEPARATION is not suitable for complex
taken to avoid being subject to rain or a flood. circuits or for those ones placed in dangerous
• Never use any worn or damaged electrical environments that could easily lead to an
cords. Electric shock or damage to the electric shock. In these cases, the end user
generator may result. must comply with local safety standards and
laws. I.E. It is possible to install an RCD (30
• Never touch the generator with wet hands or
mA) and bond neutral to the frame of the
when the generator is wet.
gen-set (refer to page 67). This operation
• Never use the generator in highly conductive must be carried out by qualified electricians
areas. These areas include metal decking and only. Now the connection to an earthling
steelwork. system become mandatory (see page 30), in
• Never handle live terminals or bare wires. order to ensure protection against indirect
contacts with live circuits by means of RCD,
• Protection against indirect contact with live use the earth terminal placed on the control
circuit parts is assured by ELECTRICAL panel of the gen-set and a high efficiency
SEPARATION. The exposed conductive parts cable.
and conductive structural parts need to be
equipotential bonded. The coils of the
alternator of the generating sets are not
bonded to the frame of the machine, therefore
the generating set MUST NOT be connected
to an earthling system. Cables length must be
under 200 m in order to properly ensure
safety for the end user. The appliances

SAFETY
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
• Do not put the generator indoors while the ignited. Keep the area around the
engine is still hot. battery well-ventilated and keep
sparks, open flame and any other
• Never jump-start the engine. Sparks caused form of ignition out of the area.
by shorting the battery to the starter terminals
may cause a fire or explosion. • Avoid serious personal injury or equipment
damage. Always turn off the battery switch (if
• Never operate the generator if powered items equipped) or disconnect the negative battery
overheat, electrical output drops, there is cable before servicing the equipment.
sparking, flames or smoke coming from the
generator or if the receptacles are damaged. Fire Hazard
• Never operate the generator closer than • Avoid personal injury or
3.3 ft (1 m) away from buildings and other equipment damage. Have
equipment or sources of combustion during appropriate safety equipment
operation. available.
Falling Hazard • Keep fire extinguishers handy in case of fire.

Avoid injury or equipment damage due to the Clearly indicate the location of the fire
generator set falling. Always secure the extinguishers with a safety sign.
generator set to prevent the generator set from
falling during maintenance. • Ensure that the type of fire extinguishers are
appropriate for material that might catch fire.
Check with local authorities.
• Have all fire extinguishers checked
periodically for proper operation and/or
readiness.
• Post evacuation routes prominently.
Periodically conduct fire drills.
Avoid personal injury. Always read and follow

safety-related precautions found on containers
of hazardous substances like parts cleaners,
primers, sealants and sealant removers.
Always wipe up all spills immediately.
The user must comply with safety regulation

applicable in the place where the genset has
been sold.

SAFETY
34127
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 • Always turn off the battery switch (if
as the flywheel or PTO shaft. equipped) or disconnect the negative battery
Keep hands, feet and tools away cable and the leads to the alternator when
from all moving parts. welding on the equipment.
• Avoid personal injury. Never leave the key in • Connect the weld clamp to the component to
the key switch when servicing the generator be welded and as close as possible to the
set. Someone may accidentally start the welding point.
engine and not realize you are servicing it.
Attach a “Do Not Operate” tag near the key • Never connect the weld clamp to the
switch while performing maintenance on the generator set or in a manner which would
equipment. allow current to pass through a mounting
bracket.
Severe Hazard • When welding is completed, reconnect the
• Avoid personal injury. Rotating leads to the engine charging system prior to
parts can cause severe injury or reconnecting the battery.
death.
•Never operate the generator Shock Hazard
without the guards in place. • Check the electrical harnesses for cracks,
abrasions and damaged or corroded
Lifting Hazard connectors. Always keep the connectors and
terminals clean.
• Avoid serious personal injury. Additional
equipment is necessary to lift the generator • Avoid serious personal injury or equipment
set. Always use lifting equipment with damage. Always turn off the battery switch (if
sufficient capacity to lift the generator. equipped) or disconnect the negative battery
cable before servicing the equipment.
• When you need to transport a generator set
for repair, have a helper assist you when • Avoid personal injury or equipment damage.
attaching it to a hoist and loading it on a Always keep the electrical connectors and
truck. terminals clean. Check the electrical
harnesses for cracks, abrasions, and
• During transportation, the generator must be
damaged or corroded connectors.
switched off, the cables must be
disconnected and the tank must be empty.
• When you need to transport a generator set
for repair, have a helper assist you when
attaching it to a hoist and loading it on a
truck.

SAFETY
WARNING 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. Always
keep hands and other body parts
Exposure Hazard away from hot generator set
To avoid injury, always wear surfaces.
personal protective equipment • Always handle hot components with
including appropriate clothing, heat-resistant gloves.
gloves, work shoes, eye and
• Never remove shields present on generator
hearing protection as required by
set. Ordinary maintenance activities can be
the task at hand.
safely carried out with shields assembled.
Slip and Trip Hazard • Before starting any maintenance activity, let
the generator set components (such as
Keep the generator free of oil, mud and other
muffler) cool down for at least 20 minutes
foreign matter.
Remove anything that creates slippery areas Tool Hazard

around the generator. Avoid personal injury or equipment damage.
Always remove any tools or shop rags used
Sudden Movement Hazard during maintenance from the area before
operation.
• Never attach tools or appliances to the
generator before it is started. Starting the
Exhaust Hazard
generator may cause sudden movement of
the equipment. Disconnect any tools and Avoid serious injury or death.
appliances from the generator before starting. Always ensure that all connections
are tightened to specifications after
• Before you start the engine make sure that all repair is made to the exhaust
bystanders are clear of the area. system. All internal combustion
• Check before starting the engine that any engines create carbon monoxide
tools or shop rags used during maintenance gas during operation and special
have been removed from the area. precautions are required to avoid
carbon monoxide poisoning.
• Always remove anything that creates slippery
areas around the generator.
• Avoid personal injury. Always stop the engine
before beginning service.

SAFETY
34127
CAUTION NOTICE
Flying Object Hazard Never attempt to modify the generator set design or
• Avoid personal injury. Always safety features such as defeating the engine speed
wear eye protection when limit control or the diesel fuel injection quantity
servicing the generator set or control.
when using compressed air or
high-pressure water. Dust, flying Modifications may impair the generator set’s safety
debris, compressed air, and performance characteristics and shorten the
pressurized water or steam may generator set’s life. Any alterations to this generator
injure your eyes. set may avoid its warranty. Always use YANMAR
• Avoid personal injury. Always wear eye genuine replacement parts.
protection when servicing the engine or when
using compressed air or high-pressure water. Always be environmentally
Dust, flying debris, compressed air, responsible.
pressurized water or steam may injure your Follow the guidelines of the
eyes. governmental agencies for the proper
disposal of hazardous materials such
Poor Lighting Hazard as engine oil, and diesel fuel. Consult the local
Avoid personal injury or equipment damage. authorities or reclamation facility.
Ensure that the work area is adequately
illuminated. Always install wire cages on Contact your authorized YANMAR industrial engine
portable safety lamps. dealer or distributor if you need to operate the
engine at high altitudes. At high altitudes the engine
Tool Hazard will lose power, run rough, and produce exhaust
Avoid personal injury or equipment damage. gases that exceed the design specifications.
Always use tools appropriate for the task at
hand and use the correct size tool for loosening • Always use correct polarity when you connect
or tightening machine parts. battery cables to the battery. This generator uses
a negative ground, 12 VDC starting system.
Before starting the engine, always turn the
• Make sure battery terminals are clean.
switches on the working appliances (lighting
apparatus, motor, etc.) to their OFF position. If • Make sure cable connections are tight.
the switches are not OFF, the sudden
application of load when the engine is started • Always shut down engine before removing or
could be very dangerous. attaching battery cables.

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

replacement parts may affect warranty coverage.

SAFETY
34127
NOTICE
If any indicator illuminates during engine operation,
stop the engine immediately. Determine the cause
and repair the problem before you continue to
operate the engine.
Never operate the generator if:
• Engine speed changes greatly
• Engine misfires often
• Powered items overheat
• Electrical output drops
• It is sparking
• It produces smoke or flames
• It vibrates at high levels
• It has a damaged receptacle
Always protect the air cleaner and electric

components from damage when you use steam or
high pressure water to clean the generator.
Always turn battery switch OFF (if equipped) or

disconnect the negative battery cable before
servicing the electrical system.
Never operate the generator set while wearing a

headset to listen to music or radio because it will be
difficult to hear warning signals.
When the engine is operated in dusty conditions,

clean the air cleaner element more frequently.
Never operate the engine with the air cleaner
element(s) removed. This may cause foreign
material to enter the engine and damage it.

SAFETY
FORESEEABLE MISUSE
Foreseeable misuse and improper applications
include, but are not limited to, the following:
- Operation not in compliance with the instructions
given into this manual.
- Operation not in compliance with safety related
instructions.
- Operation with the machine when it is not working
in perfect conditions, either functionally or in terms
of safety.
- Operation without following the
inspection/maintenance schedule.
- Any unauthorized modification of or removal of
safety equipment.
- Use of spare parts and accessories that are
unsuitable or have not been approved by Yanmar.
- Operation in flammable or hazardous
environments.
- Operation in closed-off or poorly ventilated rooms.

PRODUCT
OVERVIEW
YANMAR YDG DIESEL
GENERATOR FEATURES AND
APPLICATIONS
To achieve the highest performing miniaturized and
light-weight diesel engines, YANMAR CO., LTD.
developed the LV series single cylinder, air-cooled,
diesel engine for applications such as YANMAR
YDG generators.
YANMAR’s series of LV engines use one of the
most advanced single cylinder technologies
available.
Yanmar YDG generators are designed to supply
power to a wide variety of applications including:
• Construction
• Agriculture
• Household
We are sure that you will agree these features
provide excellent value in an industrial diesel
generator.

PRODUCT OVERVIEW
COMPONENT IDENTIFICATION
YDG3700V-5(E)BYI2 and YDG3700N-6(E)BYI2 (Typical model)
1 2 3 4 5 7 8 9 10 11 12
13
14
15
22 21 20 19 18 17 16
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 – Recoil starter
4 – Engine nameplate decal 16 – Oil filler cap/dipstick
5 – Frame 17 – Oil drain plug
6 – Control panel 18 – Oil filter
7 – Fuel tank 19 – Oil pressure switch
8 – Fuel filler cap 20 – Generator unit
9 – Starter switch (only for electric version) 21 – Generator/engine damper mounts
10 – Compression release lever 22 – Battery (only for electric version)
11 – Fuel injection pump
12 – Air cleaner
Figure 1

PRODUCT OVERVIEW
34127
YDG5500V-5(E)BYI2 and YDG5500N-6(E)BYI2 (Typical model)
1 2 3 4 5 7 8 9 10 11 12
13
14
15
22 21 20 19 18 17 16 063462-00X00
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 – Recoil starter
4 – Engine nameplate decal 16 – Oil filler cap/dipstick
5 – Frame 17 – Oil drain plug
6 – Control panel 18 – Oil filter
7 – Fuel tank 19 – Oil pressure switch
8 – Fuel filler cap 20 – Generator unit
9 – Starter switch (only for electric version) 21 – Generator/engine damper mounts
10 – Compression release lever 22 – Battery (only for electric version)
11 – Fuel injection pump
12 – Air cleaner
Figure 2

PRODUCT OVERVIEW
LOCATION OF LABELS
Safety Decals
YDG3700V-5(E)BYI2, YDG5500V-5(E)BYI2, YDG3700N-6(E)BYI2, YDG5500N-6(E)BYI2
DIESEL FUEL
ONL Y
DO NOT USE GASOLINE
H
L
CAUTION
CHECK THE ENG DO NOT OPERATE
DIESEL FUEL -INE OIL (CC CLASS) THE ENGINE IN
SAE 10W30
FLAMMABLE (OIL CHANGE EYE
STAND WATER
OR RAIN
-RY 100hr.
ENGINE MUST BE TURNED OFF
WHEN ADDING FUEL
D O N O T O P E R AT E T H E E N G I N E H
I N D O O R S O R I N P O O R LY L
V E N T I L AT E D P L A C E S .
“ S L O W ” P O S I T I O N : N O L O A D O N LY
READ OPERATION MANUAL FOR COMPLETE INSTRUCTIONS.
OPERATION
CHECK FUEL AND ENGINE OIL LEVEL BEFORE STARTING. (OPEN THE FUEL COCK)
MOVE THE ENGINE SPEED LEVEL TO THE “RUN” POSITION.
STARTING
(RECOIL) (RECOIL)
1) PULL THE STARTING ROPE SLOWLY UNTIL RETURN ENGINE SPEED LEVER
YOU FEEL RESISTANCE, RETURN ROPE. TO “STOP” POSITION.
2) PUSH THE DECOMPRESSION LEVER DOWN. (ELECTRIC)
3) PULL THE STARTER ROPE HARD AND FAST, TURN KEY TO “OFF” POSITION.
ALL THE WAY OUT. (CLOSE FUEL COCK.)
(ELECTRIC)
WARM UP ENGINE FOR ABOUT 5 MINUTES.
View Y
LOW OIL WARNING CHECK ENGINE

OIL EACH TIME
IN THE CASE OF AUTO-STOP, DO NOT RUN WITHOUT FUEL TANK IS FILLED
CHECKING OIL LEVEL SAE 10W30(CC CLASS)
Figure 3

PRODUCT OVERVIEW
34127
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: A
Serial Number: B Made in Italy: C
Performance Class: G2 Mass (dry): D
CAUTION
CHECK THE ENG DO NOT OPERATE
RATED (ISO 8528) E kW F V G A
DIESEL FUEL -INE OIL (CC CLASS) THE ENGINE IN
SAE 10W30
FLAMMABLE STAND WATER
H kW V J
(OIL CHANGE EYE OR RAIN
I A
-RY 100hr.
MAX (ISO 8528)

ENGINE MUST BE TURNED OFF
WHEN ADDING FUEL
D O N O T O P E R AT E T H E E N G I N E H
I N D O O R S O R I N P O O R LY L
V E N T I L AT E D P L A C E S .
“ S L O W ” P O S I T I O N : N O L O A D O N LY
READ OPERATION MANUAL FOR COMPLETE INSTRUCTIONS.
Frequency K Hz Power Factor 1
DIESEL FUEL
RPM L I.C. H IP 23M
ONLY
DO NOT USE GASOLINE

ALTIT. 100 m TEMP. 25 ~C
OPERATION
CHECK FUEL AND ENGINE OIL LEVEL BEFORE STARTING. (OPEN THE FUEL COCK)
MOVE THE ENGINE SPEED LEVEL TO THE “RUN” POSITION.
ŹSTARTING Ź726723(1*,1(
(RECOIL) (RECOIL)
1) PULL THE STARTING ROPE SLOWLY UNTIL RETURN ENGINE SPEED LEVER
YOU FEEL RESISTANCE, RETURN ROPE. TO “STOP” POSITION.
2) PUSH THE DECOMPRESSION LEVER DOWN. (ELECTRIC)
3) PULL THE STARTER ROPE HARD AND FAST, TURN KEY TO “OFF” POSITION.
ALL THE WAY OUT. (CLOSE FUEL COCK.)
(ELECTRIC)
WARM UP ENGINE FOR ABOUT 5 MINUTES.
Figure 4
Description of Generator Set Model Number

YDG 5500 V - 5 (E) B
Destination
Starting system
E: Electric starting
No symbol: Manual starting
Frequency
5: 50Hz
6: 60Hz
Exhaust gas emission regulations
V : Euro Stage V emission regulation
N: No emission regulation
Type
Generator series

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 MODEL
MAX. OUTPUT kW / min-1
DISPLACEMENT l
ENGINE NO.
MADE IN ITALY
Figure 7

PRODUCT OVERVIEW
34127
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. The dynamo supplies regulated electricity to the
engine systems and charges the battery while the engine is running.
The generator is equipped with a low oil shutdown feature. If the engine is
run when it is low on oil, the oil pressure will drop. The oil pressure switch
Low engine oil shutdown will sense the drop in pressure and activate the stop solenoid, which will
shut the engine down. Once the oil level is corrected, and pressure is
normal, the engine can be run again.
The engine oil filter removes contaminants and sediment from the engine oil.
Engine oil filter Periodic cleaning of the oil filter is necessary. See Periodic Maintenance Schedule
on page 47 for the frequency of cleaning.
You can fill the crankcase with engine oil from either side of the engine depending
Side filler ports (engine oil)
upon which filler port is most convenient.
Inlet and outlet fuel filters are provided to remove contaminants and sediment from
Fuel filters the diesel fuel. Periodic cleaning/replacement is required. See Periodic
Maintenance Schedule on page 47.
The fuel tank is a reservoir that holds diesel fuel. Fuel is gravity-fed to the
fuel injection pump. Since fuel is used to keep fuel system components cool
Fuel tank
and lubricated, more fuel than is necessary for combustion enters the fuel
system. Any fuel that is not used for combustion is returned to the fuel tank.
The engine oil cap/dipstick combines the oil cap and dipstick in one
Oil cap/dipstick (engine oil) assembly. The dipstick part of the assembly is used to determine the
amount of engine oil in the crankcase.
The starter motor is powered by the battery. When you turn the key switch
Starter motor to the START position, the starter motor engages with the ring gear installed
on the flywheel and starts the flywheel in motion.
The control panel houses all the controls, switches, terminals, outlets and
meters for the generator. All electrical power created by the generator is
Control panel
directed to the control panel and output is sent through various outlets and
terminals located on the control panel.
The generator is coupled to the engine to produce electrical power to
operate various loads and or machines. The generator is constructed as a
Generator
self-exciting single phase A/C, and is comprised of a stator, rotor, automatic
voltage regulator, rectifier and housing components.

PRODUCT OVERVIEW
GENERATOR CONTROL PANEL

YDG3700V-5BYI2, YDG5500V-5BYI2, YDG3700N-6BYI2, YDG5500N-6BYI2
1 2
0 240
0 V 200
~
7 6 5 4
1 – Voltage meter . 4 – 12 VDC output receptacle

2 – AC circuit breaker (For 12 VDC battery charging only)
(Generator main switch-circuit breaker) 5 – Grounding terminal
3 – DC circuit breaker (12 VDC output) 6 – Schuko socket (230V)
7 – CEE socket (230V)
Figure 8

PRODUCT OVERVIEW
34127
YDG3700V-5EBYI2, YDG5500V-5EBYI2, YDG3700N-6EBYI2, YDG5500N-6EBYI2
1 2
0 240
0 V 200
~
8 7 6 5
1 – Voltage meter . 5 – 12 VDC output receptacle

2 – AC circuit breaker (For 12 VDC battery charging only)
(Generator main switch-circuit breaker) 6 – Grounding terminal
3 – Engine start key switch 7 – Schuko socket (230V)
4 – DC circuit breaker (12 VDC output) 8 – CEE socket (230V)
Figure 9

PRODUCT OVERVIEW
AIR COOLED ENGINE

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

1
STARTER
The engines are equipped with a recoil and an
electric starter. This section explains the controls
available with the recoil starter.
Recoil Starter
K0002447A-00X
A recoil starter allows you to manually start an
engine by pulling on the recoil starter handle Figure 10
(1, Figure 10). When you pull on the handle you
set the flywheel and crankshaft in motion. The
recoil starter is spring-loaded so the handle and
attached rope automatically return to the recoil
starter assembly.
Decompression Lever
Pressing the decompression lever (2, Figure 10)
helps you start the engine by reducing the effort
needed to pull the recoil starter handle. The
decompression lever will automatically return to the
original position when the engine starts.

PRODUCT OVERVIEW
34127
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 NOTICE
switch - OFF, ON, and START.
Never hold the key in the START position for longer
than 15 seconds or the starter motor will overheat.
1 2
Engine Speed Control Lever

OFF NOTICE
ON
If using the stop lever to shut-down the engine, be
sure to return the key switch to the OFF position to
prevent discharging of the battery.
The engine speed control lever (1, Figure 12) is

3
moved to the run position (2, Figure 12) for
START generator operation. To stop the generator, turn the
key switch to the OFF position, or push down on the
STARTER stop lever (3, Figure 12) and the speed control
SW
lever (1, Figure 12), which is spring-loaded, will
K0002413A-00X move back to the stop position.
Figure 11
OFF (key straight up and down) (1, Figure 11) -
1
When you turn the key to this position the engine
shuts down. Electric current to the battery, low 2
engine oil shutdown device and other electric RUN
devices is shut off. The key can be inserted and STOP
removed from this position.

3
ON (2, Figure 11) - This is the position the key will
be in when the engine is running. After starting
engine, key switch will automatically return to this
position. K0002443A-00X
Figure 12

PRODUCT OVERVIEW

BEFORE YOU
OPERATE
INTRODUCTION
This section of the Operation Manual describes
activating a new battery, diesel fuel and engine oil
specifications and how to replenish them. It also
describes the proper way to connect the electrical
loads to the generator and the daily engine
checkout.
Before performing any storage procedures within
this section, review the Safety section on page 1.

BEFORE YOU OPERATE
BATTERY WARNING
Checking Battery Electrolyte Level Batteries contain sulfuric acid. Never allow
battery fluid to come in contact with clothing,
DANGER skin or eyes. Severe burns could result. Always
wear safety goggles and protective clothing
Never check the remaining battery charge by when servicing the battery. If battery fluid
shorting out the terminals. This will result in a contacts the eyes and/or skin, immediately
spark and may cause an explosion or fire. Use a flush the affected area with a large amount of
hydrometer to check the remaining battery clean water and obtain prompt medical
charge. treatment.
• If the engine cranking speed is so slow that the

engine does not start, recharge the battery.
• If the engine still will not start after charging, have
your authorized YANMAR industrial engine dealer
or distributor check the battery and the engine’s
1 starting system.
• If operating the machine where the ambient
temperature could drop to 14 °F (-10 °C) or less,
remove the battery from the machine at the end
of the day. Store the battery in a warm place until
2
the next use. This will help start the engine easily
at low ambient temperatures.
Figure 1
• When the amount of fluid nears the lower limit line
(2, Figure 1), remove caps and fill with distilled
water so it is at the upper limit line (1, Figure 1). If
operation continues with insufficient battery fluid,
the battery life is shortened, and the battery may
overheat and explode. During the summer, check
the fluid level more often than specified.

BEFORE YOU OPERATE
34127
Charging the Battery

1. Disconnect the battery cables from the battery.
See Disconnecting and Connecting Battery (-) (+)
Cables on page 25.
2. Clean terminals on the battery and clamps on
the end of the cables.
3. Connect the positive (+) clamp from the charger
to the positive (+) terminal on the battery.
DANGER
• If the electrolyte is frozen, slowly warm the
battery before you recharge it.
Figure 2
• Avoid serious personal injury or
equipment damage. Before charging, 5. When finished charging the battery, unplug the
remove the cap from each cell of the charger before disconnecting clamps from the
battery and always make sure there is battery. See Disconnecting and Connecting
plenty of ventilation when charging Battery Cables on page 25.
battery. Discontinue charging if the
electrolyte temperature exceeds 117 °F (45 Disconnecting and Connecting
°C). While the engine is running or the Battery Cables
battery is charging, hydrogen gas is being
produced and can be easily ignited. CAUTION
Always keep the area around the battery
well-ventilated and keep sparks, open This generator uses a negative ground 12 VDC
flames and any other form of ignition out starting system. Always shut down the engine
of the area. before removing or attaching battery cables.
Always remove the negative (–) cable first.
• Never charge the battery while connected. Always attach the negative (–) cable last
The diodes will be damaged by the high
voltage. Connect the (+) lead of the
charger to the (+) terminal of the battery, 1. When disconnecting cables, loosen and
and the (–) lead to the (–) terminal. disconnect negative (–) cable (1, Figure 3) first
Reversed polarity will damage the charger from battery.
rectifier or the battery. After charging is 2. Disconnect positive (+) cable (2, Figure 3) from
completed, connect the battery cables battery last.
correctly to the battery. Reversed polarity
wiring will damage the diodes.
Quick-charging should only be done in an
emergency; slow charging is
recommended.
4. Connect the negative (–) clamp from the

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

BEFORE YOU OPERATE
DIESEL FUEL
Diesel Fuel Specifications
(+) 2
(-) Diesel fuel should comply with the following
1 specifications. The table lists several worldwide
specifications for diesel fuels.
NOTICE
Always use diesel fuels recommended by
YANMAR for the best engine performance, to
prevent engine damage. Only use clean diesel fuel.
Figure 3
3. When connecting cables to battery connect the
positive (+) cable (1, Figure 4) first. Diesel fuel specification Location
EN590:96 European Union
CAUTION
ISO 8217 DMX International
When you install a battery, always use BS 2869-A1 or A2 United Kingdom
correct polarity when you connect battery
JIS K2204 grade No.2 Japan
cables to the battery. Always make sure the
battery terminals are clean and tight. KSM-2610 Korea
GB252 China
4. Connect the negative (–) cable (2, Figure 4) to Additional technical fuel requirements
the battery last.
• The fuel cetane number should be equal to 45 or
higher.
• The sulfur content must not exceed 0.5 % by
(+) 1 volume. Less than 0.05 % is preferred.
(-)
2 • Bio-diesel fuels. See Bio-diesel fuels on page 27.
• Never mix kerosene, used engine oil, or residual
fuels with the diesel fuel.
• Water and sediment in the fuel should not exceed
0.05 % by volume.
• Keep the fuel tank and fuel-handling equipment
Figure 4 clean at all times.
• Poor quality fuel can reduce engine performance
and/or cause engine damage.
• Fuel additives are not recommended. Some fuel
additives may cause poor engine performance.
Consult your YANMAR industrial engine dealer or
distributor for more information.

BEFORE YOU OPERATE
34127
• Ash content not to exceed 0.01 % by volume. Precautions and concerns regarding the use of
bio-fuels:
• Carbon residue content not to exceed 0.35 % by
1. Free methanol in FAME may result in corrosion
volume. Less than 0.1 % is preferred.
of aluminum and zinc FIE components.
• Total aromatics content should not exceed 35 % 2. Free water in FAME may result in plugging of
by volume. Less than 30 % is preferred. fuel filters and increased bacterial growth.
• PAH (Polycyclic Aromatic Hydrocarbons) content 3. High viscosity at low temperatures may result in
should be below 10 % by volume. fuel delivery problems, injection pump seizures,
and poor injection nozzle spray atomization.
• Metal content of Na, Mg, Si, and Al should be
equal to or lower than 1 mass ppm. (Test analysis 4. FAME may have adverse effects on some
method JPI-5S-44-95) elastomers (seal materials) and may result in
fuel leakage and dilution of the engine
• Lubricity: Wear mark of WS1.4 should be Max. lubricating oil.
0.018 in. (460 µm) at HFRR test. 5. Even bio-diesel fuels that comply with a suitable
standard as delivered, will require additional
Bio-diesel fuels
care and attention to maintain the quality of the
In Europe and in the United States, as well as some fuel in the equipment or other fuel tanks. It is
other countries, non-mineral oil based fuel important to maintain a supply of clean, fresh
resources such as RME (Rapeseed Methyl Ester) fuel. Regular flushing of the fuel system, and/or
and SOME (Soybean Methyl Ester), collectively fuel storage containers, may be necessary.
known as FAME (Fatty Acid Methyl Esters), are
6. The use of bio-diesel fuels that do not comply
being used as extenders for mineral oil derived
with the standards as agreed to by the diesel
diesel fuels.
engine manufacturers and the diesel fuel
YANMAR approves the use of bio-diesel fuels that injection equipment manufacturers, or
do not exceed a blend of 7 % (by volume) of FAME bio-diesel fuels that have degraded as per the
with 93 % (by volume) of approved mineral oil precautions and concerns above, may affect
derived diesel fuel. Such bio-diesel fuels are known the warranty coverage of your engine. See
in the marketplace as B7 diesel fuels. YANMAR Limited Warranty on page i.
These B7 diesel fuels must meet certain

requirements
1. The bio-fuels must meet the minimum
specifications for the country in which they are
used.
• In Europe, bio-diesel fuels must comply with
the European Standard EN14214 and EN590
(for Oxidation stability).
• In the United States, bio-diesel fuels must
comply with the American Standard ASTM
D-6751 and ASTM D-7467 (for Oxidation
stability).
2. Bio-fuels should be purchased only from
recognized and authorized diesel fuel suppliers.
In North America, bio-diesel and bio-diesel blends
must be purchased from the BQ-9000 accredited
producers and BQ-9000 certified distributors.

BEFORE YOU OPERATE
Filling the Fuel Tank ENGINE OIL
The YANMAR YDG generators are equipped with a
DANGER
low oil pressure stop device. This device stops the
Only fill the fuel tank with diesel fuel. Filling the engine automatically when the oil pressure falls
fuel tank with gasoline may result in a fire and below the specified level and prevents engine
will damage the engine, never refuel with the seizure when engine oil is low.
engine running.
Engine Oil Specifications
1
NOTICE
Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
engine oil. Only use the engine oil specified. Other
engine oils may affect warranty coverage, cause
internal engine components to seize, and/or
2
shorten engine life.
Use an engine oil that meets or exceeds the

following guidelines and classifications:
Service categories
• API service categories CD or higher
• ACEA service categories E-3, E-4, and E-5
K0002458A-00X • JASO service category DH-1
Figure 5 Definitions
1. Clean the area around the fuel cap. • API classification (American Petroleum Institute)
2. Remove the fuel cap (1, Figure 5) from the fuel • ACEA classification (Association des
tank. Constructeurs Européens d’Automobilies)
CAUTION • JASO (Japanese Automobile Standards
Organization)
Never remove inlet fuel screen from the filler
port when filling the fuel tank. If removed, dirt Note:
and debris could get into the fuel system
causing it to clog. • Be sure the engine oil, engine oil storage
containers, and engine oil filling equipment are
free of sediments and water.
3. Stop fueling when the fuel is at the same level
• Change the engine oil after the first 50 hours of
as the red ring (2, Figure 5) at the bottom of the
operation and then every 200 hours thereafter.
inlet fuel screen.
• Select the oil viscosity based on the ambient
DANGER temperature where the engine is being operated.
Never overfill the fuel tank. See the SAE service grade viscosity chart
(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
34127
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.
(mgKOH/g) test method; JIS K-201-5.2-2 (HCI),
ASTM D4739 (HCI). NOTICE
Engine Oil Viscosity Prevent dirt and debris from contaminating the
engine oil. Always clean the oil cap/dipstick and
Select the appropriate engine oil viscosity based on
the surrounding area before you remove the cap.
the ambient temperature using the SAE service
grade viscosity chart in (Figure 6).
3. Reinsert oil cap/dipstick into crankcase and
turn clockwise for one-half revolution to engage
SAE 10W the first thread in the crankcase opening.
SAE 20W
4. Remove oil cap/dipstick. The oil level should be
SAE 10W-30
between upper (2, Figure 7) and lower
SAE 15W-40
(3, Figure 7) lines on the oil cap/dipstick.
SAE 20
SAE 30
SAE 40
NOTICE
SAE 20W - 50 Always keep the oil level between the upper and
-4°F 14°F 32°F 50°F 68°F 86°F 104°F 122°F lower lines on the oil cap/dipstick.
(-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C) (50°C)
K0000005A00
5. Fully reinsert oil cap/dipstick (1, Figure 7) and

Figure 6 hand-tighten. Over-tightening the oil
cap/dipstick will damage it.
2 3
Figure 7

BEFORE YOU OPERATE
Adding Engine Oil GENERATOR CHECK
1. Make sure engine is level.
2. Remove oil cap/dipstick (1, Figure 7).
WARNING
3. Add indicated amount of engine oil at either one Always have a licensed electrician connect the
of the engine oil filler ports (4, Figure 7). generator to the utility circuit. The generator
must not be connected to other power sources.
4. Wait one minute and check oil level. Improper installation can cause the generator
5. Add engine oil as needed until the level is to back-feed into the utility power line. This may
between the upper (2, Figure 7) and lower electrocute a power company line repair
(3, Figure 7) lines on the oil cap/dipstick. person. Also, if the generator is powering
electrical circuits, the chance of an electrical
NOTICE fire exists.
Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
1. Only use grounded extension cords. Be sure to
damage.
use an extension cord with the proper wire
gauge size. See the following table.
6. Fully reinsert oil cap/dipstick and hand-tighten. Recommended minimum wire gauges
Over-tightening the oil cap/dipstick will damage (AWG) for extension cords
it.
AWG for length of cord
Ampere ft (m)
Engine Oil Capacity load
50 (15) 100 (30) 150 (46)
The following table shows engine oil capacities for 2 18 18 18
YANMAR YDG generators.
3 18 18 18
Dipstick 4 16 16 16
Engine/generator model 5 16 16 16
upper limit/lower limit
Engine L70V(N) 1.11/0.69 qt 6 16 16 14
generator YDG3700V(N) (1.05/0.65 L) 8 16 14 12
Engine L100V(N) 1.7/1.06 qt 10 16 14 12
generator YDG5500V(N) (1.6/1.0 L) 12 14 14 12
14 14 12 10
16 12 12 10
20 10 10 8
2. If electrical separation cannot be adopted for

indirect contact protection (see page 3),
properly ground the unit:
• Attach a #10 stranded-copper ground wire to
the ground lug.
• Drive a grounding point into the ground. The
grounding point can be a stake, grounding rod
or pipe. The grounding point should be copper
or brass.
CAUTION
Never use metal pipe that carries combustible
materials or gases to ground the generator.
Always ground the generator. Connect a
length of heavy wire between the generator
ground terminal and an external ground.

BEFORE YOU OPERATE
34127
. (1, Figure 9) shows the main AC switch on the

• Attach the ground wire to the grounding point YDG3700V-5B generator.
(1, Figure 8). You must supply the ground wire YDG3700V-5B, YDG5500V-5B
and grounding point. These are not supplied
with the generator. Follow the local safety YDG3700N-6B, YDG5500N-6B
standards. Consult your power company or a
licensed electrician. 1
YDG3700V-5B, YDG5500V-5B
YDG3700N-6B, YDG5500N-6B 0
0 V
240
200
~
0 240
0 V200
~
Figure 9
1 (1, Figure 10) shows the main AC switch on the
YDG5500V-5EB generators.
Figure 8
YDG3700V-5EB, YDG5500V-5EB
3. Select the proper load for use with the
generator set. See Selecting the Proper Load YDG3700N-6EB, YDG5500N-6EB
on page 32.
1
4. Before starting, always turn OFF the main AC
switch of the generator (1, Figure 9) or
(1, Figure 10) and any other loads. Make sure
240
nothing is plugged into or connected to the 0
0 V200
~
generator.
CAUTION
Do not start two or more appliances
simultaneously and always start them one at
a time. Never use floodlights with other
appliances. Connection with utilities must be
done only with sockets located on generator
control panel.
Figure 10

BEFORE YOU OPERATE
Selecting the Proper Load 2. Enter running watts of each item except electric
motors. The light bulb or appliance nameplate
CAUTION lists its wattage. Remember, 1 kW = 1000
watts.
• Never exceed the specified current limit for
Note: The nameplate may not list wattage.
any one electrical terminal.
It may only list volts and amps.
• Most home utility electric service is more than
60 amps. This generator will not power your • The formula for finding wattage is:
entire home. This will exceed generator volts  amps = watts.
output. Only power items needed during a • For example, an appliance nameplate states 3
power outage. Always ensure total wattage of amps at 220 volts: 3 amps  220 volts = 660
electrical load does not exceed rated wattage watts.
of generator. 3. Electric motors present a special problem when
figuring load as they require up to three times
NOTICE their rated wattage to start.
Most electric appliances require more than their • For example, an electric motor nameplate
rated wattage for start-up. states 5 amps at 220 volts.
5 amps  220 volts = 1100 watts: Running Watts
The following appliance wattage table shows Multiply this by 3. This will show the starting watts
wattage of some common household appliances. needed.
This should be used as a generic guide only.
Different manufacturers of certain products may 1100 watts  3 = 3300 watts: Starting Watts
require more wattage. See your authorized
YANMAR industrial engine dealer or distributor with NOTICE
any questions.
When figuring the generator load for motors, you
Decide what electrical load your generator can must use the Starting Watts and not the Running
power. Do this before using the generator. Use the Watts.
following four step method. It will help to select a
load that is not too large. Make sure total wattage of
Note: Some motors require nearly the
all electrical loads does not exceed the rated output
same wattage to run as to start.
capacity of your generator.
These items include saws, drills, hair
1. Make two lists of items you want powered by dryers and food mixers.
the generator. List all motors and motor 4. Add running watts and starting watts of all
powered appliances in one. List all lights and items. This total must not exceed the rated
small appliances in the other. For standby output capacity of your generator. It is a good
service to home or building, only include items idea to have up to 25 % extra capacity for future
you must power. needs or extra equipment.
CAUTION
Do not start two or more appliances
simultaneously and always start them one at
a time. Never use floodlights with other
appliances.

BEFORE YOU OPERATE
34127
Typical electrical appliance wattages

Application/equipment Running/rated watts Starting/surge watts
Light bulb (100 W) 100 100
AM/FM radio 50 - 200 50 - 200
CB radio 50 50
Fan 200 600
Television 300 - 400 300 - 400
Microwave oven 700 1000
Air conditioner (12,000 BTU) 3250 5000
Furnace fan (1/3 hp blower motor) 600 1800
Vacuum cleaner 600 750
Sump pump (1/3 hp) 700 2100
Refrigerator/freezer 800 2400
Deep freezer 500 1500
Circular saw 1000 - 2500 2300 - 4600
Circular saw 6 in. 800 1000
Floodlight 1000 1000
Drill 1/2 in. electric 1000 1250
Toaster 1200 1200
Coffee maker 1200 1200
Skillet 1200 1200
Chain saw 14 in. electric 1200 1500
Water well pump (1/2 hp) 1000 3000
Hot plate/range (per burner) 1500 1500
Table saw 10 in. 2000 6000
Water heater (storage type) 5000 5000
12 VDC battery charger 120 120

BEFORE YOU OPERATE
INITIAL ENGINE START UP Visual Checks
NOTICE CAUTION
On the initial engine start-up, allow the engine to If any problem is noted during the visual check,
run without a load for approximately 15 minutes the necessary corrective action should be
while you check for abnormal noises or vibration, taken before you operate the generator set.
diesel fuel leaks, engine oil leaks, and for proper
operation.
1. Check for engine oil leaks.
2. Check for fuel leaks.
Avoid continuous operation at maximum load for
the remainder of the first hour of operation. WARNING
During the first 10 hours of operation, check the Always wear eye protection when servicing
engine oil level frequently. See Checking Engine Oil the generator set. Never check for a fuel leak
on page 29. with your hands. Always use a piece of wood
or cardboard. Have your authorized YANMAR
dealer or distributor repair the damage.
DAILY CHECKS
Before you operate, make sure the YANMAR YDG 3. Check for damaged or missing parts.
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. Check the electrical harnesses for cracks,
generator and have any repairs completed before
abrasions and damaged or corroded
starting the generator.
connectors.
CAUTION 6. Check hoses for cracks, abrasions and
damaged, loose or corroded clamps.
It is important to perform daily checks as
periodic maintenance prevents unexpected Check Battery Electrolyte Level
downtime, reduces the number of accidents
Follow the procedures in Checking Battery
due to poor engine performance and helps
Electrolyte Level on page 24 to check the battery
extend the life of the engine.
levels.
Check Diesel Fuel and Engine Oil

• Visual checks
Levels
• Check battery electrolyte level
Follow the procedures in Filling the Fuel Tank on
• Check diesel fuel and engine oil levels page 28 and Checking Engine Oil on page 29 to
check these levels.

GENERATOR
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.

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 1
from recoil could happen, with risk of serious
injuries, if proper starting procedure is not 2
RUN
carried on. Be assured to read and understand
starting manual procedure. STOP
Recoil Start
Use the following procedure to start the engine K0001355A
using the recoil starter.

Figure 24
1. Make sure you follow the procedures stated in
Daily Checks on page 34. 6. Grasp the recoil starter handle (1, Figure 25).
2. Fill fuel tank with clean, fresh fuel. See Filling 7. Pull the handle out slowly until you feel strong
the Fuel Tank on page 28. resistance.
3. Before starting, always turn OFF the main AC 8. Slowly return the recoil starter handle to the
switch of the generator and any other loads. initial position.
Make sure nothing is plugged into or connected 9. Push the decompression lever (2, Figure 25)
to the generator. See Generator Check on down until it locks in place and then release it.
page 30.
4. Turn the key clockwise from the OFF position CAUTION
(1, Figure 23) to the ON position Always depress the decompression lever to
(2, Figure 23). allow the engine to start more quickly and
prevent damage to the recoil starter.
1
The decompression lever will automatically

2
return to the original position when the engine
OFF starts.
ON
START
STARTER
SW
K0002413C-00X
Figure 23

GENERATOR OPERATION
34127
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 2. Fill fuel tank with clean, fresh fuel. See Filling
the Fuel Tank on page 28.
3. Before starting, always turn OFF the main AC
1 switch of the generator and any other loads.
Make sure nothing is plugged into or connected
to the generator. See Generator Check on
page 30.
4. Move the engine speed control lever
(1, Figure 26) to the RUN position
(2, Figure 26).
K0002447A-00X
Figure 25
10. Grasp the recoil starter handle (1, Figure 25). 1
11. Pull the handle all the way out with a strong and 2
RUN
even motion. Use two hands if necessary.
STOP
NOTICE
Always pull recoil starter handle all the way out or
the engine will not start. Pulling out the recoil
starter handle too hard or fast will damage the
equipment. Never allow the recoil starter handle K0001355A
to snap back against the engine. Return the

Figure 26
handle to the starting position gently to prevent
damage to the recoil starter. 5. Insert the key into the key switch.
6. Turn the key clockwise to the START position
(1, Figure 27). Release the key as soon as the
12. Slowly return the recoil starter handle to the
engine starts. It will return to the ON position
initial position.
(2, Figure 27).
13. If the engine does not start, repeat this
procedure from Step 5. NOTICE
Never hold the key in the START position for
longer than 15 seconds or the starter motor will
overheat.

GENERATOR OPERATION
CHECKING THE GENERATOR

2 SET DURING OPERATION
OFF
ON 1. Check for fuel or engine oil leaks. If any leaks
are found, shut down the engine and have the
necessary repairs performed.
2. Check for abnormal sounds or vibration. If the
abnormal sounds or vibration cannot be
resolved, shut down the engine and have the
necessary repairs performed. Contact your
1
authorized YANMAR industrial engine dealer or
START distributor.
3. Check for white or black smoke from the
STARTER exhaust system. A small amount of white
SW exhaust smoke is normal on start-up of a cold
K0002413B-00X
engine. Black exhaust smoke could mean the
engine is overloaded or is being over-fueled. If
Figure 27 either of these conditions persists, contact your
7. If the engine fails to start: distributor.
• Wait until the engine comes to a complete 4. Check the fuel level during operation. If the fuel
stop before you attempt to start it again. level runs low, stop the engine and refuel. See
Filling the Fuel Tank on page 28.
NOTICE 5. If the oil pressure falls below the specified
Engaging the starter while the engine is still minimum, the low oil pressure shutdown will
rotating will result in damage to the starter motor automatically stop the engine. Check the oil
and flywheel. level and refill. See Checking Engine Oil on
page 29.
6. If the engine suddenly stops, See
• Wait at least 30 seconds before you attempt Troubleshooting on page 62, then re-make the
to start the engine again. starting procedure. If the failure remains,
contact your authorized YANMAR industrial
NOTICE engine dealer or distributor.
Waiting 30 seconds will allow the battery voltage
to recover to prevent damage to the starter motor
due to the low battery voltage.

GENERATOR OPERATION
34127
Low Load Operation SHUTTING DOWN THE

Avoid low load operation as much as possible. GENERATOR
Always operate at 1/4 load or greater when
possible. NOTICE
For maximum engine life, YANMAR recommends
NOTICE 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. This
engine at lower speeds. At full speed, the engine will allow the engine components that operate at
runs at 3000 (3600) min-1 under load. The engine high temperatures, such as the exhaust system, to
must maintain 3000 (3600) min-1 for generator to cool slightly before the engine itself is shut down.
create correct voltage. Running engine at lower
speeds will damage generator and powered items.
Follow these steps to shut down the engine:
Operating at 1/4 load or less for extended periods 1. Turn the generator main AC switch
will cause carbon to mix with unburned fuel, (1, Figure 28) OFF.
clogging the head of the injection nozzle and piston 2. With the engine speed lever in the RUN
head and fouling the muffler. Carbon buildup can position, operate the engine without load for
be recognized by bluish white smoke being emitted about five minutes.
from the engine. To avoid this, run the engine at 3/4 3. Turn the generator key switch (2, Figure 28) to
load or greater for 30 minutes or longer every 50 OFF.
hours operation.
YDG3700V-5EB, YDG5500V-5EB,
YDG3700N-6EB, YDG5500N-6EB
1 2
0 240
0 V 200
~
Figure 28
4. If the engine will not be used for six months or
longer, follow the additional instructions in
Long-Term Storage on page 69.

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
the voltage meter (1, Figure 29) or Always ensure that all appliances are in good
(1, Figure 30) indicates the voltage. If it does working order before connecting them to the
not, STOP the generator as the generator or generator. If an appliance begins to operate
voltage meter may be damaged. abnormally, becomes sluggish or stops
suddenly, turn off the generator main AC
YDG3700V-5B, YDG5500V-5B, YDG3700N-6B, switch immediately. Then disconnect the
YDG5500N-6B appliance and examine it for malfunction.
Due to high mechanical stresses, only tough
1 rubber-sheathed flexible cables are
permitted.
0 240 When using extension lines or mobile
V 200
0
~ distribution networks the resistance value
shall not exceed 1,5 Ohm.
3. Turn the main AC switch to the ON position.
NOTICE
If an overload trips the AC circuit protector,
reduce the electrical load on the circuit and
wait a few minutes before resuming
operation.
Figure 29
YDG3700V-5EB, YDG5500V-5EB
0 240
0 V 200
~
Figure 30

GENERATOR OPERATION
34127
DC APPLICATION YDG3700V-5EB, YDG5500V-5EB

NOTICE
DC terminals should be used for charging 12 VDC
batteries only. Using the DC terminals for any other 0 240
200
0 V
type of 12 VDC appliance may cause damage to ~
generator and appliance.
The DC terminal (1, Figure 31) may be used for

charging 12 volt automotive-type batteries only.
(Other loads may not be used.)
NOTICE
Never use the 12 VDC terminals at the same time
1
as the AC terminals.
1 – 12 VDC output terminal
(for 12 VDC battery charging only)
1. Always disconnect the negative (–) battery Figure 31
cable (if connected) from the battery to be
charged before charging.
WARNING
Never allow the free ends of the cables to
touch each other. If this occurs the battery
will short circuit.
2. Start the generator set.

3. Connect the charging cable to the battery
terminals and to the DC output terminals of the
generator.
NOTICE
Always connect the positive battery terminal to
the positive DC terminal on the generator. Never
reverse the charging cables or serious damage
to the generator and or battery may occur. Do not
attempt to start an automobile engine while the
generator is still connected to the battery as the
generator may be damaged.

GENERATOR OPERATION

PERIODIC
MAINTENANCE
INTRODUCTION
procedures for proper care and maintenance of the
generator set.

PERIODIC MAINTENANCE
PRECAUTIONS CAUTION
The Importance of Periodic It is important to perform daily checks. Periodic
maintenance prevents unexpected downtime,
Maintenance reduces the number of accidents due to poor
Engine deterioration and wear occurs in proportion engine performance and helps extend the life of
to length of time the generator has been in service the engine.
and the conditions the generator is subject to
during operation. Periodic maintenance prevents
unexpected downtime, reduces the number of Keep a Log of Generator Hours and
accidents due to poor machine performance and
helps extend the life of the engine. Daily Checks
Keep a log of the number of hours the generator is
CAUTION run each day and a log of the daily checks
performed. Also note the date, type of repair, and
Establish a periodic maintenance plan
parts needed for any service needed between the
according to the engine application and make
periodic maintenance intervals. Periodic
sure you perform the required periodic
maintenance intervals are every 50, 200, 400,
maintenance at intervals indicated. Failure to
1000, 1500 and 2000 hours of generator operation.
follow these guidelines will impair the engine’s
Failure to perform periodic maintenance will
safety and performance characteristics,
shorten the life of the generator.
shorten the engine’s life and may affect the
warranty coverage on your engine. See YANMAR Replacement Parts
YANMAR Limited Warranty on page i. Consult
your authorized YANMAR industrial engine Yanmar recommends that you use genuine
dealer or distributor for assistance when YANMAR parts when replacement parts are
checking items marked with a . needed. Genuine replacement parts help ensure
long generator life. Replace circuit breakers only
with components that have the same ratings and
performance.
Performing Periodic Maintenance
Perform periodic maintenance procedures in an Tools Required
open, level area free from traffic. If possible, Before you start any periodic maintenance
perform the procedures indoors to prevent procedure make sure you have the tools you need
environmental conditions, such as rain, wind, or to perform all of the required tasks.
snow, from damaging the machine.
Ask Your Authorized YANMAR
The Importance of Daily Checks
Industrial Engine Dealer or
Periodic maintenance schedules assume that the Distributor for Help
daily checks are performed on a regular basis.
Make it a habit of performing daily checks before YANMAR professional service technicians have the
the start of each shift. See Daily Checks on expertise and skills to help you with any
page 34. maintenance or service related procedures.

34127
CAUTION Tightening Fasteners

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.
not enough torque may cause a leak or component
Before starting any maintenance procedure, failure.
disconnect negative battery cable.
Attach a “Do Not Operate” tag near the key
switch while performing maintenance
procedure on the equipment.

TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS

Use the correct amount of torque when you tighten fasteners on the machine. Applying excessive torque
may damage the fastener or component and not enough torque may cause a leak or component failure.
NOTICE
The tightening torque in the following chart should be applied only to the bolts with a “7” head. (JIS strength
classification: 7T) Apply 60 % torque to bolts that are not listed. Apply 80 % torque when tightened to
aluminum alloy.
Nominal thread
Item Tightening torque Remarks
diameter  pitch
7 - 9 lb-ft
M6  1.0 mm
(87 - 104 lb-in., 9.8 -11.8 N·m, 1.0 - 1.2 kgf·m)
17 - 21 lb-ft
M8  1.25 mm
(200 - 251 lb-in., 22.6 - 28.4 N·m, 2.3 - 2.9 kgf·m)
33 - 40 lb-ft Use 80 % of the value at left
M10  1.5 mm when the tightening part is
Hexagon bolt (44.1 - 53.9 N·m, 4.5 - 5.5 kgf·m)
aluminum.
(7T) and nut 58 - 72 lb-ft
M12  1.75 mm Use 60 % of the value at left
(78.4 - 98.0 N·m, 8.0 - 10 kgf·m) for 4T bolts and locknuts.
94 - 108 lb-ft
M14  1.5 mm
(127.5 - 147.1 N·m, 13 - 15 kgf·m)
159 - 174 lb-ft
M16  1.5 mm
(215.7 - 235.4 N·m, 22 - 24 kgf·m)
7 lb-ft
1/8
(87 lb-in., 9.8 N·m, 1.0 kgf·m)
14 lb-ft
1/4
(173 lb-in., 19.6 N·m, 2.0 kgf·m)
PT plug –
22 lb-ft
3/8
(29.4 N·m, 3.0 kgf·m)
43 lb-ft
1/2
(58.8 N·m, 6.0 kgf·m)
9 - 12 lb-ft
M8
(112 - 148 lb-in., 12.7 - 16.7 N·m, 1.3 - 1.7 kgf·m)
14 - 19 lb-ft
M10
(173 - 225 lb-in., 19.6 - 25.4 N·m, 2.0 - 2.5 kgf·m)
18 - 25 lb-ft
Pipe joint bolt M12 –
(24.5 - 34.3 N·m, 2.5 - 3.5 kgf·m)
29 - 36 lb-ft
M14
(39.2 - 49.0 N·m, 4.0 - 5.0 kgf·m)
36 - 43 lb-ft
M16
(49.0 - 58.8 N·m, 5.0 - 6.0 kgf·m)
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.

34127
PERIODIC MAINTENANCE SCHEDULE

Daily and periodic maintenance is important to keep the engine in good operating condition. The following
is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary
depending on engine application, loads, diesel fuel and engine oil used and are hard to establish
definitively. The following should be treated only as a general guideline.
: Check : Replace : Contact your authorized YANMAR industrial engine dealer or distributor for these maintenance services
Periodic maintenance interval
System Check item Daily Every Every Every Every Every

Every
200 400 1000 1500 2000
50 hours
hours hours hours hours hours
Clean or replace air
cleaner element - (may
Air intake need more frequent 
service in dusty
conditions)
Adjust intake/exhaust

Cylinder head valve clearance
Check compression 
Check battery (if 
equipped) and add water Before
as necessary operation
Check battery indicator (if 
Electrical equipped) and other When
equipment driven machine indicators engine is
(if equipped) started
Wiring harness 
Voltmeter 
Inspect, clean and test
Emission control
fuel injection nozzle, if 
warranty
necessary
Check engine oil level and 
add engine oil as Before
necessary operation

Drain and refill engine oil 2nd and
 after
Engine oil 1st time 
Clean engine oil filter -
2nd and
replace if damaged
after

Check for engine oil Before
leakage and after
operation
Check for proper 
Engine speed 
operation 2nd and
control 1st time
Verify adjustment after

: Check : Replace : Contact your authorized YANMAR industrial engine dealer or distributor for these maintenance services
Periodic maintenance interval
System Check item Daily Every Every Every Every Every

Every
200 400 1000 1500 2000
50 hours
hours hours hours hours hours

Check spark arrester for
Exhaust system Before
clogging (if equipped)
operation

Check fuel tank level and
Before
add fuel as necessary
operation
Drain and clean fuel tank 
Clean inlet fuel screen 
Fuel
Replace outlet fuel filter  

Before
Check for fuel leakage
and after
operation

or every 2
Replace fuel system years
Hoses
hose(s) whicheve
r comes
first
Check brushes for wear

or damage
Check slip rings for wear

or damage
Generator
Check coils and
Automatic Voltage

Regulator (AVR) for
correct operation
Check main and sub

frames for damage
Check engine/frame
Frame dampers for wear, 
damage and tightness
Check all fasteners for

Note: These procedures are considered normal maintenance and are performed at the owners expense.

34127
PERIODIC MAINTENANCE Check engine speed control

PROCEDURES Before you operate the driven machine check the
engine speed control. See Check and adjust
engine speed control on page 55.
Daily, Before Operation
Before performing periodic maintenance

procedures, read the complete procedure including
safety information.
Perform the following maintenance daily before
operation.
• Check battery
• Check battery indicator
• Check engine oil level
• Check for engine oil leakage
• Check engine speed control (first time only)
• Check spark arrester
• Check fuel level
• Check for fuel leakage
Check battery
Check the battery electrolyte level. See Checking
Battery Electrolyte Level on page 24.
Check battery indicator

Visually check the battery indicator (if equipped)
and any other indicator provided by the driven
machine manufacturer.
Check engine oil level

Before you operate the engine check the engine oil
level. See Checking Engine Oil on page 29.
Check for engine oil leakage

Before you operate the engine check for any engine
oil leaks. If you discover any engine oil leaks,
contact your authorized YANMAR industrial engine
dealer or distributor for service.

Check fuel level
Daily, After Operation
Before you operate the engine, check the fuel level.
See Filling the Fuel Tank on page 28.
• Check for engine oil leakage
* Check for fuel leakage • Check for fuel leakage
Before you operate the engine, check for any fuel
leaks. Check for engine oil leakage
After you shut down the engine check for any
DANGER engine oil leaks.
Avoid personal injury. Always wear eye
protection when checking for fuel leaks and WARNING
never check for a fuel leak with your hands. 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
After you shut down the engine check for any fuel
leaks.
DANGER
protection when checking for fuel leaks and
never check for a fuel leak with your hands.
Always use a piece of wood or cardboard. Have
your authorized YANMAR dealer or distributor
repair the damage.

34127
After Initial 50 Hours of Operation 1
Perform the following maintenance after the initial

50 hours of operation.
• Replace engine oil 2 3
• Clean/inspect engine oil filter 4

Replace engine oil
The engine oil on a new engine becomes
contaminated from the initial break-in of internal Figure 32
parts. The initial 50 hour oil change and filter 6. Remove the oil cap/dipstick (1, Figure 32) to
cleaning is very important. allow the engine oil to drain more easily.
NOTICE
Drain the engine oil as follows:
Prevent dirt and debris from contaminating the
1. Make sure the engine is level. engine oil. Carefully clean the oil cap/dipstick
2. Start the engine and bring it up to operating and the surrounding area before you remove the
temperature. cap.
3. Stop the engine.
4. Position a container under the engine to collect 7. After all oil has been drained from the engine,
waste oil. reinstall the drain plug (2, Figure 32) and
5. Remove one of the drain plugs located on the tighten to 173 - 208 lb-in. (19.6 - 23.5 N·m,
bottom of the cylinder block (2, Figure 32). 2.0 - 2.4 kgf·m).
Allow oil to drain.
WARNING
The engine oil will be hot after engine
operation, stay clear of the hot engine oil to
avoid being burned. Always wear eye
protection.

. 8. Dispose of used oil properly.
NOTICE
NOTICE Never overfill. Overfilling may result in white
Always be environmentally responsible. Follow exhaust smoke, engine overspeed or internal
the guidelines of the governmental agencies for damage.
the proper disposal of hazardous materials such
as engine oil, diesel fuel and engine coolant.
Consult the local authorities or reclamation
facility. Never dispose of hazardous materials by 1
dumping them into a sewer, on the ground or into
ground water or waterways.
2 3
9. Inspect engine oil filter. See Clean/inspect
engine oil filter on page 53.
4
10. Add engine oil until the level is between the
upper (2, Figure 33) and lower (3, Figure 33)
lines on the oil cap/dipstick (1, Figure 33). See
Figure 33
Adding Engine Oil on page 30.
11. Warm up the engine by running it for five
minutes and check for any engine oil leaks.
12. After engine is warm, shut it off and let it sit for
10 minutes.
13. Recheck the engine oil level by reinserting the
oil cap/dipstick into the crankcase and turn
clockwise for one-half revolution to engage the
first thread in the crankcase opening. See
Checking Engine Oil on page 29.
14. Add oil if necessary.
NOTICE
Always keep the oil level between the upper and
lower lines on the oil cap/dipstick.
15. Replace the oil cap/dipstick and tighten by

hand. Over-tightening may damage the cap. If
any engine oil is spilled, wipe it away with a
clean cloth.

34127
Clean/inspect engine oil filter

NOTICE
Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed, or internal
damage.
3 2 1
9. Warm up the engine by running it for five
minutes and check for any engine oil leaks.
10. After engine is warm, shut it off and let it sit for
10 minutes.
4
11. Recheck the engine oil level by reinserting the
K0001123B-00X
oil cap/dipstick into the crankcase and turn
Figure 34 clockwise for one-half revolution to engage the
first thread in the crankcase opening. See
It is recommended that this procedure be Checking Engine Oil on page 29.
performed at the same time as the Replace engine 12. Add oil if necessary.
oil procedure on page 51.
NOTICE
1. Remove the oil filter retaining bolt Always keep the oil level between the upper and
(1, Figure 34). lower lines on the oil cap/dipstick.
2. Drain engine oil. See Replace engine oil on
page 51.
13. Replace the oil cap/dipstick (1, Figure 33) and
3. Pull the oil filter cap (2, Figure 34) out and tighten by hand. Over-tightening may damage
remove the oil filter (3, Figure 34). the cap. If any engine oil is spilled, wipe it away
4. Clean the oil filter in suitable parts cleaner or with a clean cloth.
replace if damaged.
5. Lubricate the O-ring (4, Figure 34) with oil and
reinstall the oil filter (3, Figure 34).
Applicable engine oil filter Part No.
L70V and L100V 114250-35070
6. Make sure the oil filter cap (2, Figure 34) is fully
seated.
7. Reinstall and tighten the oil filter retaining bolt
(1, Figure 34).
8. Add new engine oil to the engine as specified in
Adding Engine Oil on page 30.

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
• Test GFCI outlet • Replace engine oil and clean/inspect engine
oil filter
Clean inlet fuel screen
• Check engine speed control
1. Clean the area around the fuel cap
(1, Figure 35). • Drain the fuel tank and replace outlet fuel filter
2. Remove the fuel cap from the fuel tank.
Clean air cleaner element
1 Engine performance is adversely affected when the
air cleaner element is clogged with dust. Be sure to
2 clean or replace the air cleaner element
periodically.
3
Avoid operating in extremely dusty conditions.
When the engine is operated in dusty conditions,
clean the air cleaner element more frequently.
Never operate the engine with the air cleaner
element(s) removed. This may cause foreign
material to enter the engine and damage it.
Clean or replace the air cleaner element if the air
intake restriction exceeds the following
specifications:
K0002456A-00X (L100V: 0.21 psi (1.47 kPa; 150 mmAq) or less),

(L70V: 0.20 psi (1.37 kPa; 140 mmAq) or less).
Figure 35
3. Lift out the inlet fuel screen (3, Figure 35).
CAUTION
Wipe up all spills immediately.
4. Clean the inlet fuel screen using suitable parts

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

34127
L70V and 100V models

The L70V and 100V model engines use a “dry” 2 3 4 5
1
type air filter element. The air filter element is an
open paper type element. This type of air filter
element should be cleaned or replaced every 200
hours or earlier if found excessively dirty.
CAUTION
protection when servicing the engine or when
using compressed air or high pressure water. K0001549A-00X
Dust, flying debris, compressed air,
pressurized water or steam may injure your Figure 36
eyes.
9. Reinstall the air cleaner element (4, Figure 36)
into the air cleaner housing.
1. Remove the wing nut (1, Figure 36). 10. Slide the outer foam element (5, Figure 36)
2. Remove the air cleaner cover (2, Figure 36). over the air cleaner element (4, Figure 36).
3. Remove the wing nut (3, Figure 36). 11. Reinstall the wing nut (3, Figure 36) and
4. Remove the air cleaner element (4, Figure 36) hand-tighten. Over-tightening the wing nut will
and outer foam element (5, Figure 36). damage the air cleaner assembly.
5. Blow air through both elements using 12. Reinstall the air cleaner cover (2, Figure 36).
42 - 71 psi (0.29 - 0.49 MPa, 3.0 - 5.0 kgf/cm2) 13. Reinstall the wing nut (1, Figure 36) and
compressed air to remove any debris. Blow air hand-tighten. Over-tightening the wing nut will
from the inside to the outside of the filter damage the air cleaner assembly.
element using the lowest possible air pressure
to remove dust without damaging the elements. Replace engine oil and clean/inspect
engine oil filter
6. Check the condition of the air filter element by
shining a flashlight from the back of the air filter Change the engine oil every 200 hours of operation
element. If light is not visible on the outside of after the initial change at 50 hours. Clean and
the air filter element, replace the air filter inspect the engine oil filter at the same time. See
element. Replace engine oil on page 51 and Clean/inspect
engine oil filter on page 53.
Air cleaner element Part No.
L70V and L100V 114210-12590 Check and adjust engine speed control
After you operate the engine for 200 hours, check
7. If either element is damaged replace both of the engine speed control.
them. (They are not sold individually.)
Never attempt to adjust the low or high idle speed
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
distributor.

A constant speed control device is used on YDG Drain the fuel tank and replace outlet fuel
generator sets, to govern the engine speed to a filter
pre-set constant engine speed under various loads.
1. Position an approved container under the fuel
When moved to the full throttle position, the speed
tank to collect the fuel.
control lever “locks” at full throttle.
Never force the throttle lever to move. This may DANGER
deform the governor lever and cause irregular Always wipe up all spills immediately. Diesel
operation of the engine speed control. fuel is flammable and explosive under certain
Always run the engine at full speed. Never run conditions. Store any containers containing
engine at lower speeds. At full speed, the engine fuel in a well-ventilated area, away from any
runs at 3000 (3600) min-1 under load. The engine combustibles or sources of ignition. Wipe up
must maintain 3000 (3600) min-1 for generator to all spills immediately and never use a shop
create correct voltage. Running engine at lower rag to catch spilled fuel.
speeds will damage generator and powered items.
2. Remove the fuel cap (1, Figure 38).
1. Check that the speed control lever 3. Remove the fuel tank drain plug (8, Figure 38)
(1, Figure 37) operates smoothly and locks into and gasket (9, Figure 38) to drain the fuel.
the full speed RUN position (2, Figure 37) Inspect the gasket and replace if damaged.
when advanced and returns to the stop position
when the stop lever (3, Figure 37) is actuated. NOTICE
If the speed control lever does not operate as 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.
Consult the local authorities or reclamation
facility.
1
2 4. Remove clamps (2, Figure 38) and disconnect
RUN fuel supply (3, Figure 38) and return lines
STOP (4, Figure 38).
3
5. Remove the fuel tank mounting bolts and
remove the fuel tank from the generator frame.
6. Remove the three fuel filter nuts (5, Figure 38)
and pull the fuel filter (6, Figure 38) out through
K0001355C-00X
bottom of the tank.
1 – Speed control lever
2 – RUN position
3 – Stop lever
Figure 37

34127
Every 400 Hours of Operation

1
Perform the following maintenance every 400 hours
of operation.
• Adjust intake and exhaust valve clearance
• Check brushes for wear or damage
9
• Check slip rings for wear or damage
8 • Check coils and Automatic Voltage Regulator
(AVR) for correct operation
7 2
• Check main and sub-frames for damage
4
6 • Check all fasteners for damage and tightness
2
3 Adjust intake and exhaust valve
5
K0002457B-00X
clearance
Proper adjustment is necessary to maintain the
Figure 38 correct timing for opening and closing the valves.
Improper adjustment will cause the engine to run
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. service.
9. Reinstall the drain plug and gasket.
Check brushes for wear or damage
10. Reinstall the fuel tank into the generator frame
and secure with mounting bolts. Check the generator brushes for wear and damage.
Generator brushes wear with normal use of the
11. Reconnect the fuel supply and return lines to generator over time. It is important to check the
the tank with clamps. condition of the brushes to ensure generator
12. Fill the fuel tank with fuel and inspect for leaks. performance is maintained at an optimum. See
Repair or replace components as necessary. your authorized YANMAR industrial engine dealer
or distributor for this service.
Check slip rings for wear or damage

Check the generator slip rings for wear and
damage. Generator slip rings wear with normal use
of the generator over time. It is important to check
the condition of the slip rings to ensure generator
performance is maintained at an optimum. See
your authorized YANMAR industrial engine dealer
or distributor for this service.

Check coils and Automatic Voltage
Regulator (AVR) for correct operation Every 1000 Hours of Operation
Check the generator coils and AVR for correct
Perform the following maintenance every 1000
operation and output. It is important to check the
hours of operation.
condition of the generator coils and AVR to ensure
generator performance is maintained at an • Check compression
optimum. See your authorized YANMAR industrial
engine dealer or distributor for this service. • Check engine/frame dampers for wear,
Check main and sub-frames for damage
Check compression
Check the main frame and sub-frames for damage.
The main and sub-frames are the structural support An engine compression check is required every
for the engine, generator, fuel tank and all other 1000 hours to obtain optimum engine performance.
generator controls and components. Any damage See your authorized YANMAR industrial engine
to the frames, including corrosion may compromise dealer or distributor for this service.
the structural integrity of the frame and should be
Checkengine/frame dampers for wear,
repaired or replaced to avoid costly repairs and/or
personal injury. See your authorized YANMAR damage and tightness
industrial engine dealer or distributor for service Inspect all frame components for damage and
and replacement parts. repair or replace as required.
Check all fasteners for damage and The damper mount butyl rubber has excellent
tightness shock absorption performance. Prevent
contamination of the damper with diesel oil or
Check all fasteners used on the generator set. All gasoline as much as possible during operation, to
fasteners should be properly installed and prevent deterioration of the rubber damper. See
tightened to the specified value given in the YDG your authorized YANMAR industrial engine dealer
Service Manual. See your authorized YANMAR or distributor for service and replacement parts.
industrial engine dealer or distributor for service
and replacement parts. 1. Check for separation at rubber baked portion
(1, Figure 39).
2. Check the damper rubber material
(2, Figure 39) for cracks and deformation.
Replace the damper if cracked or deformed.
K0002858-00X
Figure 39

34127
Every 1500 Hours of Operation Every 2000 Hours of Operation
Perform the following maintenance every 1500 Perform the following maintenance every 2000
hours of operation. hours of operation.
• Inspect, clean and test fuel injection nozzle • Check and replace fuel hoses
Inspect, clean and test fuel injection Check and replace fuel hoses
nozzle, if necessary Regularly check the fuel system hoses. If they are
Proper operation of the fuel injectors is required to cracked or degraded, replace them. Replace
obtain the optimum injection pattern for full engine rubberized fuel hoses every two years or every
performance. See your authorized YANMAR 2000 hours of engine operation, whichever comes
industrial engine dealer or distributor for this first, even if the engine has been out of service.
service. Rubberized fuel lines tend to dry out and become
brittle after two years or 2000 hours of engine
operation, whichever comes first.

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.

TROUBLESHOOTING
TROUBLESHOOTING 4. Operating conditions when problem occurs:
INFORMATION • Load on engine

• Color of exhaust smoke
If your generator does not operate properly, refer to
the Troubleshooting Chart on page 62 or see your • Type of diesel fuel
authorized YANMAR industrial engine dealer or • Type of engine oil
distributor. You can refer to Troubleshooting Chart • Any abnormal noises or vibration
on page 62 even if your generator suddenly stops.
• Operating environment such as high altitude or
Provide the authorized YANMAR industrial engine extreme ambient temperatures
dealer or distributor with the following information: 5. Maintenance history and previous problems.
1. Model name and serial number of your 6. Other factors that contribute to the problem.
generator.
The YDG generator set model and serial number
information label is located inside the top front
frame rail. See Generator Set Decal on page 15.
2. Model name and serial number of your engine.
The engine nameplate is located on the cooling
shroud on the PTO side of engine above the
starter. See Engine Nameplate (Typical) on
page 16.
3. How long the generator has been in service
(the number of generator hours or the number
of calendar months).

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

Engine does not start
Filling the Fuel Tank on
No diesel fuel Refuel fuel system
page 28
Engine control lever not in the Move engine control lever to the
–
RUN position RUN position
Engine oil level low Check and fill oil to proper level –
Diesel Fuel
Replace with recommended
Improper diesel fuel Specifications on page
diesel fuel
Starter motor operates but 26
engine does not start Clogged engine oil filter Replace engine oil filter –
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 –
Engine starts with recoil starter
Key switch not in the ON position Turn key to the ON position –
but then stops
Battery needs charging Check electrolyte, recharge –
Disconnecting and
Starter motor does not operate Faulty cable connection at
Clean terminals, retighten Connecting Battery
or rotates too slowly (engine can battery terminals
Cables on page 25
be turned manually)
Faulty starter switch –
Faulty starter motor –
industrial engine dealer or
Engine cannot be turned distributor
Inner parts seized or damaged –
manually
White or black exhaust smoke
Engine overloaded Reduce load –
Clean air cleaner
Clogged air cleaner element Clean element or replace
element on page 54
Diesel Fuel
Black exhaust smoke Improper diesel fuel Specifications on page
diesel fuel
26
Faulty spraying of fuel injection See authorized YANMAR –
Excessive intake/exhaust valve industrial engine dealer or
distributor –
clearance
Diesel Fuel
Improper diesel fuel Specifications on page
diesel fuel
26
White exhaust smoke Faulty spray pattern of fuel
See authorized YANMAR –
injection
Fuel injection timing delay –
distributor
Engine burning oil –

TROUBLESHOOTING
34127
Symptom Probable cause Action Refer to

Generator
Generator Check on
Main switch is off Turn main switch on
page 30
Equipment incorrectly connected
Connect the equipment correctly –
to generator
Defective AVR See authorized YANMAR –
Winding short circulated or loose industrial engine dealer or
distributor –
connections
No electricity generated Electrical load too high Reduce electrical load –
Loss of residual magnetism See authorized YANMAR –
Engine speed too low distributor –
Defective rotor diode

Defective stator See authorized YANMAR –
Defective rotor distributor –
Engine not running properly –
Demagnetized machine –
AVR fuse interrupted –
Faulty AVR See authorized YANMAR –
Lack of no-load voltage Winding failure industrial engine dealer or –
distributor
Insulation failure –
Wrong or incorrectly carried out
–
connections
Faulty AVR –
Too low or too high no-load
Winding failure –
voltage
Faulty slip-ring –
Faulty AVR industrial engine dealer or –
Too low load voltage distributor
Possible overload Check load current value –
Too high load voltage Faulty AVR industrial engine dealer or –
distributor
Faulty AVR industrial engine dealer or –
Unstable voltage distributor
Turn off and restart the
Protections activated –
equipment
Possible overload Check load current value –
Overheating See authorized YANMAR

Alternator inlet or outlet openings
industrial engine dealer or –
are clogged
distributor
Noisy alternator Bearing broken industrial engine dealer or –
distributor

TROUBLESHOOTING
ELECTRICAL WIRING DIAGRAM

YDG3700V-5B, YDG5500V-5B, YDG3700N-6B, YDG5500N-6B
STOP
SOLENOID
BU RE
BU RE
ALTERNATOR
AVR
RELAY
BL
OIL
PRESSURE FREQ. JUMPER
SWITCH
BL
GE VOLTAGE TRIMMER
RE
BL + AC COIL AC COIL
DC AC
TERMINALS COIL BL BR BU RE
-
+ -
AUX
DC BREAKER GE ROTOR
COIL
COIL
4P
BL VOLTMETER
AC
BL BREAKER V
RE BR
BR BU
BU
BL Black
RE Red
BR
BU Blue YE/GR
BR Brown EARTH
TERMINAL
GE Grey
BU
YE/GR Yellow/Green YE/GR
YE/GR
AC 230 V AC 230 V
SCHUKO SOCKET CEE SOCKET
Figure 40

34127
YDG3700V-5EB,
STOP BAT BAT
SOLENOID IG
KEY IG
ST ST
SWITCH B
BU RE B
E E
BL GR RE YE
BU RE
BL
ALTERNATOR
YDG5500V-5EB, , YDG3700N-6EB, YDG5500N-6EB

AVR
STARTER
RELAY
GR/WH
BL
OIL
PRESSURE RECTIFIER BL/RE
SWITCH FREQ. JUMPER
BL GE
RE VOLTAGE TRIMMER
GR/WH
+ - +
AC AC COIL AC COIL
DC BL BATTERY
COIL BL
TERMINAL
-
BL BR BU RE
+ -
DC BREAKER GE AUX
COIL ROTOR GR/WH
Figure 41
COIL
4P
CHARGE
BL VOLTMETER COIL
GR/WH
BL
AC BREAKER V
RE BR
BR BU GR/WH
BU
BL Black
RE Red
YE Yellow
GR Green
TROUBLESHOOTING
KEY SWITCH OPERATION DIAGRAM
BU BR
Blue
E B IG BAT ST YE/GR
BR Brown
OFF OFF EARTH
GE Grey TERMINAL
I
I YE/GR Yellow/Green
BU YE/GR
II II BL/RE Black/Red
GR/WH Green/White YE/GR
AC 230 V AC 230 V
SCHUKO CEE
SOCKET SOCKET
65
TROUBLESHOOTING
ELECTRICAL EQUIPMENTS’
CONNECTIONS
(under “Electrical Separation” condition)
THE GENSET MUST BE PLACED ON A

NON CONDUCTIVE SURFACE
(SEE ASIDE FIGURE)
INSULATING MATERIAL
(I.E. WOOD, RUBBER, ETC.)
L1 PE N L1 PE N
- x2 CLASS II EQUIPMENT;
- NO GROUNDING;
L1 PE N L1 PE N
- x1 CLASS I EQUIPMENT;
- NO GROUNDING;
L1 PE N L1 PE N
- x1 CLASS I EQUIPMENT;
- x1 CLASS II EQUIPMENT;
- NO GROUNDING;
NOT PERMISSIBLE
L1 PE N L1 PE N
- x2 CLASS I
EQUIPMENT;

TROUBLESHOOTING
34127
(/(&75,&$/(48,30(176¶&211(&7,216
71V\VWHPZLWK5&'
L1 PE N L1 PE N
:,5,1*',$*5$0
)255&' 127,1&
/8'(',16&23(2)
6833/<
/ 1
/HJHQG
&/$66,,(48,30(17
&/$66,(48,30(17
($57+187 ($57+52'

TROUBLESHOOTING

LONG-TERM
STORAGE
INTRODUCTION
procedures necessary to place the generator into
long-term storage (three months or longer) and
how to prepare it for operation.

LONG-TERM STORAGE
BEFORE YOU PLACE THE RETURNING THE ENGINE TO

GENERATOR IN LONG-TERM SERVICE
STORAGE 1. Perform the Daily Checks on page 34.
1. Perform the next periodic maintenance 2. Start the engine. Allow the engine to run
procedure. For example, if there are 10 hours without load for approximately 5 to 10 minutes
remaining before the 200 hour maintenance, while you check for:
you should do the maintenance before you • abnormal noises or vibration
place the engine in storage. See Periodic
• fuel and engine oil leaks
Maintenance Schedule on page 47.
2. Start the engine. Allow the engine to run DANGER
without load for approximately five minutes and
then stop the engine.
protection when checking for fuel leaks and
3. Drain the engine oil while the engine is still never check for a fuel leak with your hands.
warm and fill with new oil. See Replace engine Always use a piece of wood or cardboard.
oil on page 51. Have your authorized YANMAR dealer or
4. Push the decompression lever down and hold it distributor repair the damage.
while slowly pulling the recoil starter two or
three times. Do not start the engine.
3. Avoid prolonged operation at maximum load for
5. Pull the decompression lever up. Pull the recoil
the remainder of the first hour of operation.
starter slowly and stop when there is
resistance. This procedure closes the intake
and exhaust valves in the compression position
and helps prevent rust.
6. Allow the engine to completely cool then drain
the fuel tank or fill it completely.
7. Protect the air cleaner, muffler and electrical
components (dynamo, starter motor, switches)
from water and dust.
8. Disconnect the negative (-) battery cable to
prevent the battery from discharging.
9. Check the battery fluid and add distilled water
as required. See Check Battery Electrolyte
Level on page 34.
10. Charge the battery once a month during
storage. See Charging the Battery on page 25.
11. Clean the generator and store it in a dry place.
NOTICE
Always protect the air cleaner and electric
components from damage when you use steam
or high pressure water to clean the generator.
12. Rotate the engine without starting, every four to

six months.

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)
Frequency 60 Hz ±1% (±2% on transient)
3.4 kVA 5.2 kVA
Rated output
DC12 V - 10 A
Rated voltage 240 V ±2%
Rated current 14.2 A 21.7 A
Generator
Power factor 1.0

Phase Single-phase
No. of poles 2
Type of insulation H-class
Bearing system Ball bearing (grease-enclosed)
AC AC240 V/16 A
Output terminal
DC Terminal (-: Black, +: Red)
AC 14 A (NFB) 22 A (NFB)
Breaker
DC 12 A (thermal breaker)
Voltmeter AC300 V
Emergency stop system Engine stop device by low level oil sensor
L 650 mm 720 mm
Dimension W 496 mm 480 mm
H 530 mm 578 mm
Generator
Protection IP23M
unit
Performance Class (ISO8528-8) G2

Quality Class (ISO8528-8) B
Vibation Level Amp [Avg]1mm - Acc [RMS] 52.4m/s2 Amp [Avg]1mm - Acc [RMS] 55.5 m/s2
Dry weight 71 kg (81 kg) 96 kg (106 kg)

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)
Frequency 50 Hz ±1% (±2% on transient)
3.0 kVA 4.5 kVA
Rated output
DC12 V - 10 A
Rated voltage 230 V ±2%
Rated current 13 A 19.6 A
Generator
Power factor 1.0

Phase Single-phase
No. of poles 2
Type of insulation H-class
Bearing system Ball bearing (grease-enclosed)
AC AC230 V/16 A
Output terminal
DC Terminal (-: Black, +: Red)
AC 13 A (NFB) 20 A (NFB)
Breaker
DC 12 A (thermal breaker)
Voltmeter AC300 V
Emergency stop system Engine stop device by low level oil sensor
L 650 mm 720 mm
Dimension W 496 mm 480 mm
H 530 mm 578 mm
Generator
Protection IP23M
unit
Performance Class (ISO8528-8) G2

Quality Class (ISO8528-8) B
Vibation Level Amp [Avg]1mm - Acc [RMS] 51.7m/s2 Amp [Avg]1mm - Acc [RMS] 54.7 m/s2
Dry weight 71 kg (81 kg) 96 kg (106 kg)

SPECIFICATIONS
34127
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 1
Bore × stroke 78 × 67 mm 86 × 75 mm
Displacement 0.320 L 0.435 L
Compression ratio 20 20
RPM (min-1) 3600 3600
hp SAE 5.9 8.9
Continuous rated output
kW 4.4 6.6
PS 6.0 9.0
RPM (min-1) 3000 3000
hp SAE 6.6 9.9
Max. rated output (net)
kW 4.9 7.4
PS 6.0 10
High idling RPM (min-1) 3800 3800
Fuel injection timing bTDC by FIC 20° 20°
Valve clearance 0.15 ± 0.05 mm
PTO position Crankshaft
Direction of rotation Counterclockwise viewed from PTO side
Fuel injection pump –
Fuel injection nozzle –
Valve opening pressure 200 kgf/cm2
Fuel selection See Diesel Fuel on page 26
Fuel filter 5 µm
Governor All speed type, mechanical
Balancer shaft Single shaft
with electric start 41.0 kg 53.5 kg
Engine weight (dry)
without electric start 36.0 kg 48.5 kg
Cooling system Forced air by flywheel fan
Lubricating system Forced lubrication with trochoid pump
Oil selection See Engine Oil on page 28.
Oil filter Resin, 60 mesh
Permissible angle of inclination 20° (momentary 30°)
Air cleaner Dry-type paper element filter
Muffler Expansion silencer with cover

SPECIFICATIONS
Engine model L70N6-G(E)YDG2 L100N6-G(E)YDG2

(Generator) YDG3700N-6(E)B YDG5500N-6(E)B
Starting system Electric start/recoil start
L 354 mm 367 mm
Dimensions W 436 mm 459 mm
H 453 mm 492 mm
Upper limit 1.05 L 1.6 L
Oil capacity
Lower limit 0.65 L 1.0 L
Fuel tank capacity 13.0 L
Battery capacity 35 Ah
Note:
1. Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric condition: Room temperature 77 °F (25 °C), atmospheric pressure 29.53 in. Hg (100 kPa,
750 mm Hg), relative humidity 30 %
• Fuel temperature at fuel injector pump inlet: 104 °F (40 °C)
• With cooling fan, air cleaner, muffler: YANMAR standard
• After engine break-in period. Output allowable deviation: ±3 %
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW

SPECIFICATIONS
34127
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 1
Bore × stroke 78 × 67 mm 86 × 75 mm
Displacement 0.320 L 0.435 L
Compression ratio 21.1 21.2
RPM (min-1) 3000 3000
hp SAE 5.4 7.6
Continuous rated output
kW 4.0 5.7
PS 5.4 7.7
RPM (min-1) 3000 3000
hp SAE 5.9 8.4
Max. rated output (net)
kW 4.4 6.3
PS 6.0 8.6
High idling RPM (min-1) 3175 3175
Fuel injection timing bTDC by FIC 13.5° 13.0°
Valve clearance 0.15 ± 0.05 mm
PTO position Crankshaft
Direction of rotation Counterclockwise viewed from PTO side
Fuel injection pump –
Fuel injection nozzle –
Valve opening pressure 200 kgf/cm2
Fuel selection See Diesel Fuel on page 26
Fuel filter 5 µm
Governor All speed type, mechanical
Balancer shaft Single shaft
with electric start 41.0 kg 53.5 kg
Engine weight (dry)
without electric start 36.0 kg 48.5 kg
Cooling system Forced air by flywheel fan
Lubricating system Forced lubrication with trochoid pump
Oil selection See Engine Oil on page 28.
Oil filter Resin, 60 mesh
Permissible angle of inclination 20° (momentary 30°)
Air cleaner Dry-type paper element filter
Muffler Expansion silencer with cover

SPECIFICATIONS
Engine model L70V5-G(E)YDG2 L100V5-G(E)YDG2

(Generator) YDG3700V-5(E)B YDG5500V-5(E)B
Starting system Electric start/recoil start
L 354 mm 367 mm
Dimensions W 436 mm 459 mm
H 453 mm 492 mm
Upper limit 1.05 L 1.6 L
Oil capacity
Lower limit 0.65 L 1.0 L
Fuel tank capacity 13.0 L
Battery capacity 35 Ah
Note:
2. Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric condition: Room temperature 77 °F (25 °C), atmospheric pressure 29.53 in. Hg (100 kPa,
750 mm Hg), relative humidity 30 %
• Fuel temperature at fuel injector pump inlet: 104 °F (40 °C)
• With cooling fan, air cleaner, muffler: YANMAR standard
• After engine break-in period. Output allowable deviation: ±3 %
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW
Basing on altitude working conditions a derating factor for available

genset output power must be applied, according to the following graph:
DERATING PERCENTAGE vs ALTITUDE

0
-5
DERATING [%]
-10
-15
-20
-25
0 250 500 750 1000 1250 1500 1750 2000
ALTITUDE [m]

Yanmar Energy System Co., Ltd.
Umeda Gate Tower
1-9, Tsurunocho, Kita-ku, Osaka, Japan
Yanmar America Corporation

101 International Parkway
Adairsville, GA 30103, U.S.A.
TEL: +1-770-877-9894 FAX: +1-770-877-9009
https://www.yanmar.com/us/
Yanmar Europe B.V.

Brugplein11, 1332 BS Almere -de Vaart
The Netherlands.
TEL: +31-36-5493200 FAX: +31-36-5493209
https://www.yanmar.com/eu/
Yanmar Asia (Singapore) Corporation Pte Ltd.

4 Tuas Lane, Singapore 638613
TEL: +65-6861-3855 FAX: +65-6862-5189
https://www.yanmar.com/sg/
Yanmar Engine (Shanghai) Corporation Ltd.

1101-1106 Gopher Center Building, No.757
Meng Zi Road Shanghai, China P.R.C. 200023
TEL: +86-21-2312-0688 FAX: +86-21-6880-8682
http://www.yanmar-china.com/cn/
Yanmar South America Industria De Maquinas Ltda.

Av. Presidente Vargas 1400, Indaiatuba, S.P., Brazil, CEP: 13338-901
TEL: +55-19-3801-9224 FAX: +55-19-3875-3899, 2241
https://www.yanmar.com/br/
As of December 31, 2020
OPERATION MANUAL
ORIGINAL INSTRUCTIONS
YDG3700V-5BYI2, YDG3700V-5EBYI2,
YDG5500V-5BYI2, YDG5500V-5EBYI2
YDG3700N-6BYI2, YDG3700N-6EBYI2,
YDG5500N-6BYI2, YDG5500N-6EBYI2
1st edition: October 2021
Issued by: YANMAR ITALY S.p.A.

Edited by: YANMAR ITALY S.p.A. ENGINEERING DEPARTMENT
YANMAR ITALY S.p.A
YIYDG-EN0000
http://www.yanmaritaly.it 2021.10

YANMAR Operation Manual YDG Series

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OPERATION

DIESEL POWERED GENERATORS

All Rights Reserved:

MODEL YDG3700V-5EBYI2, YDG3700V-5BYI2, YDG5500V-5EBYI2, YDG5500V-5BYI2

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

How Long is the Warranty Period?

YDG Operation Manual i

What the Generator Owner must Do:

To Locate an Authorized YANMAR Industrial Engine Dealer or Distributor:

What YANMAR will Do:

ii YDG Operation Manual

YANMAR limited warranty - continued

What is not Covered by this Warranty?

YDG Operation Manual iii

Retail Purchaser Registration

iv YDG Operation Manual

YDG Operation Manual v

vi YDG Operation Manual

Manufacturer: YANMAR ITALY s.p.a.

We DECLARE hereby, under our sole responsibility

And with the following harmonised standards:

Machinery: EN 12100, UNI EN ISO 8528-1, UNI EN ISO 8528-13

Name and address of the pearson authorized to compile and

Ing. Carlo Cavallero

YDG Operation Manual vii

This Page Intentionally Left Blank

viii YDG Operation Manual

YDG Operation Manual ix

x YDG Operation Manual

Daily Checks ..................................................................................... 34

YDG Operation Manual xi

This Page Intentionally Left Blank

xii YDG Operation Manual

YDG Operation Manual 1

SAFETY PRECAUTIONS DANGER

2 YDG Operation Manual

connected to the sockets of the gen-set,

YDG Operation Manual 3

Falling Hazard • Keep fire extinguishers handy in case of fire.

Avoid personal injury. Always read and follow

Always wipe up all spills immediately.

The user must comply with safety regulation

4 YDG Operation Manual

YDG Operation Manual 5

Remove anything that creates slippery areas Tool Hazard

6 YDG Operation Manual

YDG Operation Manual 7

Only use replacement parts specified. Other

8 YDG Operation Manual

Always protect the air cleaner and electric

Always turn battery switch OFF (if equipped) or

Never operate the generator set while wearing a

When the engine is operated in dusty conditions,

YDG Operation Manual 9

10 YDG Operation Manual

YDG Operation Manual 11

1 – Muffler 13 – Generator set model and serial number decal

12 YDG Operation Manual

YDG5500V-5(E)BYI2 and YDG5500N-6(E)BYI2 (Typical model)