Part of the Yanmar Repair Manuals.
A YDG that cranks clean but gives you nothing at the receptacles can eat a whole afternoon while the loads it should be carrying sit dead. The troubleshooting chart and electrical wiring diagram in this manual let you work through that fault in order instead of guessing, and the maintenance schedule keeps you from landing there in the first place.
Yanmar published it as operation manual 0AYDG0-G0000 for the YDG2700EV-6EH, YDG3700EV-6EI, and YDG5500EV-6EI diesel powered generators, built on the L48V6-GY, L70V6-GY, and L100V6-GY engines (2005 to 2007). Its 146 pages cover battery activation, diesel fuel and oil specifications, starting and shutdown, AC and DC application, periodic maintenance with a standard torque chart, long term storage, and principal specifications for all three models.
The PDF is bookmarked with 152 entries and prints cleanly, so it lives on your phone or in the binder next to the generator, wherever that happens to be.
What's Inside This Yanmar YDG Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 3-4 | Record of Ownership |
| Yanmar Warranties | 5-12 | Yanmar Limited Warranty (What Is Covered by This Warranty?, How Long Is the Warranty Period?, What the Generator Owner Must Do, To Locate an Authorized Yanmar Industrial Engine Dealer or Distributor, What Yanmar Will Do, What Is Not Covered by This Warranty?, Warranty Limitations, Warranty Modifications, Questions, Retail Purchaser Registration) |
| Safety | 17-34 | - |
| Product Overview | 35-50 | Yanmar Ydg Diesel Generator Features and Applications, Component Identification |
| Before You Operate | 51-76 | Battery (Activating the Battery), Diesel Fuel (Specifications, Filling the Fuel Tank), Engine Oil (Specifications, Viscosity, Checking Engine Oil, Adding Engine Oil, Capacity) |
| Generator Operation | 77-96 | Starting Generator, Checking the Generator During Operation, Shutting Down the Generator, AC Application, DC Application |
| Periodic Maintenance | 97-132 | Precautions, Standard Torque Chart, Periodic Maintenance Schedule, Periodic Maintenance Procedures |
| Troublesh Ooting | 133-138 | Troubleshooting Chart, Troubleshooting Information, Electrical Wiring Diagram |
| Long Term Storage | 139-142 | Before You Place the Generator in Long Term Storage, Returning the Engine to Service |
| Specifications | 143-146 | Principal Specifications |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening Torque M6×1.0 | 10.8 ± 1.0 N·m | p. 114 |
| Tightening Torque M8×1.25 | 25.5 ± 2.9 N·m | p. 114 |
| Battery electrolyte fill volume | 1.9 qt (1.8 L) | p. 59 |
| Battery electrolyte level | Between upper and lower level lines | p. 125 |
| Inlet fuel screen cleaning/replacement interval | Every 50 hours | p. 116 |
| Outlet fuel filter replacement interval | Every 200 hours | p. 116 |
| Air cleaner element cleaning/replacement interval | Every 200 hours | p. 116 |
| Air cleaner element cleaning air pressure | 42-71 psi (0.29−0.49 MPa, 3.0−5.0 kgf/cm2) | p. 128 |
| Frequency | 60 Hz | p. 143 |
| Rotor Shaft Speed | 3600 rpm (min-1) | p. 143 |
| Power Factor | 1 | p. 143 |
| DC Output | 12V - 8.3A (100W) | p. 143 |
Yanmar YDG Series Common Problems This Manual Covers
Engine runs but no AC output
A YDG that starts fine after sitting idle yet produces no voltage at the receptacles is one of the most reported faults on these units. The troubleshooting chart and the electrical wiring diagram give you a sequence to isolate the cause instead of swapping parts blind.
Manual Section: Troubleshooting p. 133Unstable speed or output under load
Hunting RPM or sagging output when load comes on is an unsafe condition, not a quirk. The operation section covers what to check while the generator is running, proper AC and DC application, and correct shutdown so you can tell overload from a genuine fault.
Manual Section: Generator Operation p. 77Hard starting after long storage
These generators often refuse to start after months unused, usually from stale fuel or a flat battery. The storage section covers both preparing the unit before it sits and the return-to-service steps that get it running again without damage.
Manual Section: Long Term Storage p. 139Fuel starvation from clogged filters
Misfiring, smoke, or the engine bogging under load frequently traces back to restricted fuel delivery. The maintenance schedule sets the inlet fuel screen at every 50 hours and the outlet fuel filter at every 200 hours, with the procedures to do both.
Manual Section: Periodic Maintenance p. 97Weak cranking and battery faults
Poor cranking on the electric-start models is usually the battery or its connections rather than the starter. The pre-operation section covers activating the battery, the 1.9 qt (1.8 L) electrolyte fill, and polarity and connection checks before the first start.
Manual Section: Before You Operate p. 51Power loss from dirty air cleaner
A plugged air cleaner element chokes these small air-cooled diesels into smoke and lost output. The maintenance procedures call for cleaning or replacing the element every 200 hours, using compressed air at 42-71 psi (0.29-0.49 MPa).
Manual Section: Periodic Maintenance p. 97Frequently Asked Questions
Which generator models does this manual cover?
It covers the Yanmar YDG2700EV-6EH, YDG3700EV-6EI, and YDG5500EV-6EI diesel powered generators from 2005 to 2007, powered by the L48V6-GY, L70V6-GY, and L100V6-GY engines. It is Yanmar publication 0AYDG0-G0000, in English.
Does it include an electrical wiring diagram?
Yes. The Troubleshooting section includes the electrical wiring diagram along with a troubleshooting chart, which is what you need when the engine runs but the generator produces no output. p. 133
What are the engine oil capacities for the Yanmar YDG Series diesel generators?
Per the Specifications section, oil capacity to the dipstick upper limit is 0.85 qt (0.8 L) on the YDG2700EV-6EH, 1.11 qt (1.05 L) on the YDG3700EV-6EI, and 1.7 qt (1.6 L) on the YDG5500EV-6EI. p. 143
How often do the fuel filters need service?
The Periodic Maintenance section schedules the inlet fuel screen for cleaning or replacement every 50 hours and the outlet fuel filter for replacement every 200 hours, and it includes the step-by-step procedures plus a standard torque chart for reassembly. p. 97
How quickly can I access this manual after buying?
This is a 146-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Can I print this manual?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
Does this Yanmar YDG2700EV-6EH manual have electrical schematics?
Included. The Yanmar YDG2700EV-6EH, YDG3700EV-6EI, YDG5500EV-6EI Operation Manual provides a wiring diagram for the electrical system.
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