Yanmar YDG Series Industrial Diesel Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the Yanmar air-cooled diesel generator model YDG series has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Yanmar YDG2700N
Yanmar YDG3700N
Yanmar YDG5500N
Yanmar YDG6600TN


TABLE OF CONTENTS :

1. Safety
2. Name of Generator Set
3. Outline of Generator Set
4. Structure of Generator Set
5. Disassembly and Assembly
6. Inspection and Maintenance
7. Adjustment Procedures
8. Quality Standards for Fuels and Lubricants
9. Operation and Storage Methods and Load Selection
10. Periodic Inspection Items
11. Circuits
12. Machines, Tools, Instruments and Other Materials for Inspection and Maintenance
13. Service Standards
14. Bolts and Nuts Tightening Torques
15. Troubleshooting
16. Appendix


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 0BYDG-G00300
Total Pages : 131


This 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. OBLNO-G00100)

This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover
Foreword
Contents
1. Safety
1.1 Waming Symbols
1.2 Safety Precautions
1.2.1 Service Shop(Location)
1.2.2 Working Wear
1.2.3 Tools to be Used
1.2.4 Parts and Lubricants
1.2.5 Bolt Tightening Torque
1.2.6 Electrical Equipment
1.2.7 Product Handling
1.2.8 Waste Disposal
2. Name of Generator Set
2.1 How to Read the Model Name
3. Outline of Generator Set
3.1 Specifications
3.2 Sectional Views of Engine and Generator Set
3.2.1 Front view
3.2.2 Side views
4. Structure of Generator Set
4.1 Outline of Structure
4.2 Frame Unit
4.3 Control Panel Unit
4.4 Generator Unit
4.5 Engine Unit
4.5.1 Engine Body
4.5.2 Intake and Exhaust System
4.5.3 Lubricating System
4.5.4 Fuel System
4.5.5 Govemor and Operating System
4.5.6 Cooling and Starting System
5. Disassembly and Assembly
5.1 Before Starting Operation
5.1.1 Grasp of Service HIstory
5.1.2 Preparing the Necessary Tools, Parts and Materials
5.2 Disassembly and Assembly Pricedures
5.2.1 General Instructions
5.2.2 Frame Unit
5.2.3 Control Panel Unit
5.2.4 Generator Unit
5.2.5 Engine Unit
6. Inspection and Maintenance
6.1 Frame Unit
6.1.1 Fuel Tank
6.1.2 Fuel Hose
6.1.3 Damper
6.1.4 Battery and Battery Cable
6.2 Control Panel Unit
6.2.1 Breaker and Switches
6.2.2 Voltmeter
6.2.3 Wire Hamess
6.3 Generator Unit
6.3.1 General Instructions
6.3.2 Electrical Parts Inspection and Quality Check Procedure
6.3.3 Ball Bearing
6.3.4 Slip Ring
6.3.5 Brush
6.3.6 Coil, AVR and Rectifier
6.3.7 Voltage and Resistance table
6.4 Engine Unit
6.4.1 General Instructions
6.4.2 Fuel Injection valve
6.4.3 Fuel Injection Pump
6.4.4 Oil Pressure Sender
6.4.5 Filters
6.4.6 Liner, Piston and Intake/Materials
7. Adjustment Procedures
7.1 Before Starting Operation
7.1.1 Preparing Tools, Parts and Materials
7.2 Intake/Exhaust Vaive
7.2.1 Adjustment Procedure
7.3 Fuel Injection Valve
7.3.1 Adjustment Procedure
7.4 Fuel Injection Pump
7.4.1 Adjustment Procedure
7.4.2 Output Decrease and Model Selection for Use in Highland
7.5 Fuel Injection Controller
7.5.1 Adjustment Procedure
7.6 Emergency Stop Function
7.6.1 Outline of Emergency Stop System
7.6.2 Adjustment Procedure
7.7 Govemor
7.7.1 Preparation for Adjustment
7.7.2 Adjustment Procedure
8. Quality Standards for Fuels and Lubricants
8.1 Fuels
8.1.1 Standards and Characteristics
8.1.2 Notes Relative to Storage
8.2 Lubricants
8.2.1 API Service Clssification(Standard)
8.2.2 SAE Viscosity Classification(Standard)
8.2.3 Notes on Lubricant Selection
9. Operation and Storage Methods and Load Selection
9.1 General Notes
9.2 Inspection and Preparation for Operation
9.2.1 Addition of Fuel
9.2.2 Lubricant Supply
9.2.3 Cleaning and Replacement of Filrters
9.2.4 Battery and Starter Motor Inspection
9.2.5 Operating Place selection and Hoisting and Installation Procedures
9.2.6 Grounding
9.3 Load Condition and Preparation
9.3.1 Load Condition
9.3.2 Load Estimation for Operating load
9.3.3 Load Connection Conditions and Methods
9.4 Starting, Stopping and Loading Procedures
9.4.1 General Notes
9.4.2 Inspection Before and After Operation
9.4.3 Starting and Stopping Procedures
9.4.4 Loading Procedure
9.5 Action Before and After Long-period Storage
9.5.1 Storage Procedure
9.5.2 Action After Storage
10. Periodic Inspection Items
10.1 Inspection Items and Intervals
11. Circuits
11.1 Electrical Circuit
11.1.1 How to read Electrical Circuit Diagrams
11.1.2 Electrical Circuit Diagrams
11.2 Fuel Circuit
11.2.1 Fuel Circuit Diagrams
11.3 Lubrication Circuit
11.3.1 Lubrication Circuit Diagram
12. Machines, Tools, Instruments and Other Materials for Inspection and Maintenance
12.1 Machines, Tools and Instruments
12.1.1 General Tools
12.1.2 Special tools
12.1.3 Measuring Instruments
12.2 Materials Required
13. Service Standards
13.1 Adjustment Standards
13.2 General Standards
14. Bolts and Nuts Tightening Torques
14.1 General Instructions
14.2 Major Bolts and Nuts
14.3 General Bolts and Nuts
15. Troubleshooting
15.1 Trouble Phwenomena and Defective Parts
15.2 Troubleshooting procedures
16. Appendix
16.1 Fuel and lubricant qualities are important
16.1.1 Composition of illustrations
16.1.2 How to and what to read from the illustrastion
16.1.3 Why doesfuel pollute the atomosphere by combusion are become harmful to living things?
16.1.4 Why is lubricant also deteriorated by fuel?
16.1.5 What are influences and effects by viscosity and additives of fuel and lubricant?
16.1.6 Why is the engine performance adversely affected by poor fuel or lubricant quality?
16.2 Is required power of load machine estimated correctly?
16.2.1 Required power of load machine is greater than the indicated capacity
16.2.2 The power factor greatly varies by load machine type and at rated operation and at start
16.2.3 Method for obtaining required power of load machine
16.2.4 Practice of obtaining required power
16.2.5 Total required power varies by the order of starting load machine s
16.2.6 Notes for operatinig load machines without causing malfunctions to the generator
16.2.7 Method for determining the generator specification
Back Cover

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