This Yanmar industrial engines YDG2700N YDG3700N YDG5500N YDG6600TN 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-N Series Service Manual (Pub. No. 0BLN0-G00100) 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
1. 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
2. Name of Generator Set ..2-1
2.1 How to Read the Model Name 2-1
3. Outline of Generator Set ..3-1
3.1 Specifications ..3-1
3.2 Sectional Views of Engine and Generator Set 3-2
3.2.1 Front view .3-2
3.2.2 Side views 3-2
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
- ii – - iii -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 Panel 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 Panel 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
6.4 Engine Unit 6-11
6.4.1 General Instructions .6-11
6.4.2 Fuel Injection Valve ..6-11
6.4.3 Fuel Injection Pump ..6-13
6.4.4 Oil Pressure Sender .6-14
6.4.5 Filters 6-15
6.4.6 Liner, Piston and Intake/Exhaust Valve ..6-16
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
2. Name of Generator Set ..2-1
2.1 How to Read the Model Name 2-1
3. Outline of Generator Set ..3-1
3.1 Specifications ..3-1
3.2 Sectional Views of Engine and Generator Set 3-2
3.2.1 Front view .3-2
3.2.2 Side views 3-2
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
- ii – - iii -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 Panel 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 Panel 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
6.4 Engine Unit 6-11
6.4.1 General Instructions .6-11
6.4.2 Fuel Injection Valve ..6-11
6.4.3 Fuel Injection Pump ..6-13
6.4.4 Oil Pressure Sender .6-14
6.4.5 Filters 6-15
6.4.6 Liner, Piston and Intake/Exhaust Valve ..6-16
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