YANMAR DIESEL ENGINE YDG2700EE-6EH YDG3700EE -6EI YDG5500EE-6EI SERVICE REPAIR MANUAL

This YDG Series YDG2700EE-6EH YDG3700EE -6EI YDG5500EE-6EI manual explains the service procedure for Yanmar air-cooled diesel generator model YDG series. Please use this manual for correct, quick, safe servicing of the diesel generator sets. For the engine servicing, refer to the Industrial Diesel Engine Model L-A Series Service Manual (Pub. No. OOOOAOA5012-9108 or A0A50012T9018) or Model: L48EE · L70EE · L100EE Service Manual (Pub. No. M9961-H11310) for the EPA and ARB-OR certified engines. Please be advised that the contents of this manual may be different from actual generator set because of any later modifications of parts or specifications for improving the generator quality.

CONTENTS

Safety . … 1-1
1.1 Warning  Symbols 1-1
1.2 Safety  precautions 1 ~2
1.2.1 Service  Shop  (Location) 1-2
1.2.2 Working  Wear 1 -3
1.2.3 Tools to  Be Used 1-3
1.2.4 Parts  and  Lubricants 1 -3
1.2.5 Bolt  Tightening  Torque . . 1 -3
1.2.6 Electrical  Equipment 1-4
1.2.7 Product  Handling……. . 1 -5
1.2.8 Waste  Disposal 1-6

.Name of Generator Set . . 2-1
2.1 How to  Read the  Model  Name 2-1

Outline of  Generator Set . . 3-1
3.1 Specifications 3-1
3.1.1 Southeast Asia and  Philippines 3-1
3.1.2 Taiwan 3-5
3.1.3 Australia 3-7
3.1.4 Saudi Arabia 3-9
3.1.5 Germany,  Holland  and  Italy 3-10

3.1.7 U.S.A and Canada 3-13
3.2 Performances 3-14
3.2.1 Southeast Asia and  Philippines 3-14
3.2.2 Taiwan 3-18
3.2.3 Australia 3-20
3.2.4 Saudi Arabia 3-22
3.2.5 Germany,  Holland  and  Italy 3-23
3.2.6 Norway 3-25
3.2.7 U.S.A.  and Canada 3-26
3.3 Sectional Views  of  Engine and  Generator Set 3-27
3.3.1 Front  View 3-27
3.3.2 Side  Views 3-27

3.4 External  Views  and  Components  of Generator Set 3-28
3.4.1 Southeast Asia  and  Philippines 3-28
3.4.2 Taiwan 3-32
3.4.3 Australia 3-34
3.4.4 Saudi  Arabia 3-36
3.4.5 Germany,  Holland and  Italy 3-37
3.4.6 Norway 3-39
3.4.7 U.S.A.  and  Canada 3-40

4. Structure of  Generator Set 4-1
4.1 Outline of  Structure 4-1
4.2 Frame  Unit . 4-1
4.3 Control  Panel  Unit 4-2
4.4 Generator  Unit 4-3
4.5 Engine  Unit . . 4-4
4.5.1 Engine  Body 4-4
4.5.2 Intake and  Exhaust  System 4-5
4.5.3 Lubricating  System 4-6
4.5.4 Fuel  System 4-7
4.5.5 Governor and  Operating  System ….. 4-8
4.5.6 Cooling  and  Starting  System 4-9

5. Disassembly and  Assembly 5-1
5.1 Before  Starting  Operation 5-1
5.1.1 Grasp of  Service  History 5-1
5.1.2 Preparing the  Necessary Tools,  Parts  and  Materials 5-1
5.2 Disassembly and  Assembly  Procedures 5-1
5.2.1 General  Instructions 5-1
5.2.2 Frame  Unit 5-2
5.2.3 Control  Unit 5-3
5.2.4 Generator Unit 5-3
5.2.5 Engine  Unit 5-4

6. Inspection  and  Maintenance 6-1
6.1 Frame  Unit 6-1
6.1.1 Fuel Tank 6-1
6.1.2 Fuel  Hose 6-1
6.1.3 Damper 6-1
6.1.4 Battery and  Battery  Cable 6-2

6.2 Control  Unit 6-4
6.2.1 Breaker and  Switches 6-4
6.2.2 Voltmeter 6-4
6.2.3 Wire  Harness 6-4
6.3 Generator  Unit 6-5
6.3.1 General  Instructions 6-5
6.3.2 Electrical  Parts  Inspection  and  Quality  Check Procedure 6-6
6.3.3 Ball  Bearing 6-8
6.3.4 Slip  Ring 6-8
6.3.5 Brush 6-9
6.3.6 Coil,  AVR  and  Rectifier 6-9
6.3.7 Voltage  and  Resistance Table 6-10
1) Southeast Asia and  Philippines 6-10
2) Taiwan 6-11
3) Australia 6-12
4) Saudi  Arabia .  6-13
5) Germany,  Holland  and  Italy 6-14
6) Norway 6-15
7) U.S.A.  and  Canada 6-16
6.4 Engine  Unit 6-17
6.4.1 General  Instructions 6-17
6.4.2 Fuel  Injection  Valve 6-17
6.4.3 Fuel  Injection  Pump 6-19
6.4.4 Oil  Pressure  Sender 6-20
6.4.5 Filters 6-21
6.4.6 Liner,  Piston  and  Intake/Exhaust  Valve 6-22

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