Yanmar 6LY3-STC Operation Manual
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Yanmar 6LY3-STC Operation Manual

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6LY3
series
OPERATION MANUAL
6LY3–STC
6LY3–UTC
P/N: 0ALY3–G00200
MARINE
ENGINE

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Summary of Contents for Yanmar 6LY3-STC

  • Page 1 6LY3 series OPERATION MANUAL 6LY3–STC 6LY3–UTC P/N: 0ALY3–G00200 MARINE ENGINE...
  • Page 2 / or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Yanmar and registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries.

  • Page 3: Table Of Contents

    Safety Precautions............4 General Information ..........4 Before You Operate ..........4 During Operation and Maintenance ......4 Location of Labels............8 Product Overview..............9 Yanmar 6LY3 Features and Applications......9 New Engine Break-In..........9 Component Identification..........11 Service Side............11 Non-Service Side ..........12 Nameplate..............13 Function of Major Components........14...
  • Page 4 Keep a Log of Engine Hours and Daily Checks..... 45 Yanmar Replacement Parts ........45 Tools Required ............. 45 Ask Your Authorized Yanmar Marine Dealer for Help ..45 Required EPA Maintenance - USA Only ..... 45 EPA Installation Requirements - USA Only ....46 Tightening Fasteners..........
  • Page 5 Returning the Engine to Service........70 Specifications..............71 Principal Engine Specifications........71 Wiring Diagrams............ 73 EPA Warranty USA Only............77 Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only..............77 Your Warranty Rights and Obligations: ....... 78 Warranty Period: ........... 78 Warranty Coverage: ..........79 Exclusions: ............
  • Page 6 TABLE OF CONTENTS This Page Intentionally Left Blank 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 7: Introduction

    RCD. (instrument panel, fuel tank, etc.) described in this manual may differ from To help you enjoy your Yanmar 6LY3 engine ones installed on your vessel. Please refer for many years to come, please follow these to the manual provided by the recommendations: manufacturer of these components.

  • Page 8: Record Of Ownership

    INTRODUCTION RECORD OF OWNERSHIP Take a few moments to record the information you need when you contact Yanmar for service, parts or literature. Engine Model: Engine Serial No.: Date Purchased: Dealer: Dealer Phone: 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 9: Safety

    SAFETY Yanmar considers safety of great DANGER importance and recommends that anyone that comes into close contact with its Indicates an hazardous situation which, if products, such as those that install, operate, not avoided, will result in death or serious maintain or service Yanmar products, injury.

  • Page 10: Safety Precautions

    • Safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar Marine dealer or distributor for additional training. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 11 Store any equipment in a designated area it will be difficult to hear the warning signals. away from moving parts. NEVER use the engine compartment for storage. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 12 NEVER check for a fuel leak with your loosening or tightening machine parts. hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar Flying Object Hazard Marine dealer or distributor repair the ALWAYS wear eye protection when damage.
  • Page 13 SAFETY If a Yanmar Marine engine is installed at an NOTICE angle that exceeds the specifications stated The safety messages that follow have in the Yanmar Marine installation manuals, NOTICE level hazards. engine oil may enter the combustion chamber, causing excessive engine speed,...

  • Page 14: Location Of Labels

    SAFETY LOCATION OF LABELS 120324-07240 Figure 1 shows the location of regulatory and safety labels on Yanmar 6LY3 series engines. Please replace if damaged or lost. 128296-07260 0002079 Figure 1 128296-07350 1 – Part Number: 128296-07300 2 – Part Number: 120324-07240 3 –...

  • Page 15: Product Overview

    Any auxiliary equipment attached to the engine A new Yanmar diesel engine must be should be easy to use and accessible for operated at suitable speeds and power service. To handle the drive equipment,...
  • Page 16 To complete engine break-in, perform After valve. Initial 50 Hours maintenance procedures. See Periodic Maintenance Schedule on page 47. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 17: Component Identification

    2 – Coolant Fill Cap 7 – Inter-Cooler 3 – Electronic Control Unit Cover 8 – Flywheel Plate 9 – Air Intake Silencer 4 – Fuel Injection Pump 10–Turbocharger 5 – Lube Oil Cooler 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 18: Non-Service Side

    1 – Coolant Tank (Exhaust Manifold) 5 – Alternator 2 – Dipstick 6 – V-Belt 3 – Freshwater Cooler 7 – Fuel Filter 4 – Seawater Pump 8 – Freshwater Pump 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 19: Nameplate

    Check the engine model, output, rpm and serial number on the nameplate. Model Gear Model Continuous power kW Speed of prop,shaf t Fuel stop power kW ENG.No. 0006472 Figure 3 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 20: Function Of Major Components

    Nameplates are provided on the engine and the marine gear and include the mod- Nameplates el, serial number and other data. Starter Starter motor for the engine. Powered by the battery. Alternator Driven by V-belt and generates electricity and charges the battery. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 21: Electronic Control System (Ecs)

    PRODUCT OVERVIEW ELECTRONIC CONTROL See Yanmar Electronic Control System SYSTEM (ECS) Operation Manual for LY3 Engines for a more complete description of the electronic control system (ECS). the control equipment consists of the rocker switch panel, the display, engine interface...

  • Page 22: Display

    Note: When starting the engine, make it a Display Function rule to check for any highlighted alarms. If Runtime Engine Data Tri-Screen the system does not function normally, (Figure 5) contact your authorized Yanmar Marine dealer and ask for diagnostics. SINGLE OIL PRES DUAL PORT Alarms...

  • Page 23: Rocker Switch Panel

    • To stop the engine, push bottom half of Eng ON switch (OFF). Note: The engine will take 2 to 7 seconds to stop running after the bottom of the rocker switch is pressed. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 24: Control Head Shift And Throttle

    • N (or NEUTRAL) Button – If the associated For Instrument Panel wiring diagrams, control head lever is in the “Neutral Idle” please contact your authorized Yanmar position, pushing this button engages / Marine dealer or distributor, or refer to the...
  • Page 25 Disengage: 1. Return the handle(s) to N (neutral) (Figure 13, (4)). 2. Press the N (neutral) button(s) (Figure 13, (5)). The neutral light(s) glow steady (Figure 13, (5)). 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 26 (Figure 14, (3)). Press the N (neutral) button next to the lever on the control head. The N (Neutral) lamp will stop flashing, indicating that the Split Range Throttle has been disengaged. SELECT SYNC 0002045 Figure 14 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 27: Dc-Dc Converter

    5% of each other and are above 20% throttle. Disengage: Press the SYNC button on the control head. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 28: Outline Drawing

    Check the normal operation when the instrument pan- Fuse replacement procedure el key switch is turned to the ON position Output side: 13.8V±5% Replace the 15A glass tube in the 24V+ input side. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 29: Before You Operate

    Safety section on Diesel Fuel Specifications page 4. NOTICE: Only use diesel fuels recommended by Yanmar Marine for the best engine performance, to prevent engine damage and to comply with EPA warranty requirements. Only use clean diesel fuel.

  • Page 30: Specifications

    BEFORE YOU OPERATE Bio-Diesel Fuels Precautions and concerns regarding the use of bio-fuels: Yanmar approves the use of biodiesel fuels • Biodiesel fuels have a higher content of that do not exceed a blend of 5% non- methyl-esters, which may deteriorate...

  • Page 31: Handling Of Diesel Fuel

    6 – Fuel Tank Drain Cock 7 – Approximately 50 mm (1.95 in.) 8 – Fuel Shutoff Valve 9 – Less Than 500 mm (19.68 in.) 10–To Fuel Injection Pump 0004512 Figure 1 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 32: Filling The Fuel Tank

    NOTICE: NEVER use the starter motor to crank the engine to bleed the fuel system. This may cause the starter motor to overheat and damage the coils, pinion and / or ring gear. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 33: Engine Oil

    • Select the oil viscosity based on the ambient temperature where the engine is being operated. See the SAE Service Grade Viscosity Chart (Figure 3). • Yanmar does not recommend the use of engine oil “additives.” SAE 10W-30 SAE 15W-40 -4°F...

  • Page 34: Engine Oil Viscosity

    / dipstick. 3. Hand-tighten the filler port (Figure 4, (2)) cap securely. Selection of Marine Gear Oil 0002051 Refer to the instruction book for each marine Figure 4 gear. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 35: Engine Coolant

    Replace the engine coolant periodically, temperature range. according to the maintenance section in this Operation Manual. Remove scale from the cooling system periodically by flushing the system. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 36: Filling Heat Exchanger With Engine Coolant

    2 – Coolant Tank (Heat Exchanger) checking the coolant tank. Steam can 3 – Seawater Drain Cock spray out during engine operation if 4 – Freshwater Drain Cock the cap is loose. 5 – Seawater Pump 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 37 When engine coolant is supplied for the first time or when it has been replaced, conduct a trial operation of the engine for about 5 minutes and check the quantity of engine oil and coolant. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 38 BEFORE YOU OPERATE This Page Intentionally Left Blank 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 39: Engine Operation

    All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 40 • If the ambient temperature is below -16C (+5F), rubber components such as gaskets and seals will harden, causing premature engine wear and damage. • Contact your authorized Yanmar Marine engine dealer or distributor if the engine will be operated outside of this standard temperature range.

  • Page 41: Starting The Engine

    NOTICE: Never hold the key in the start position for longer than 15 seconds or the starter motor will overheat. Electronic Controls PORT Ver 3.00P COPYRIGHT 2006 TELEFLEX, INC. i5601E 0002057 Figure 2 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 42: If The Engine Fails To Start

    Operate the engine normally. joint? CAUTION! The engine will seize if it is operated when seawater discharge is too small or if load is applied without any warming up operation. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 43: Shifting

    Reverse Detent. The marine gear will shift into REVERSE. The engine will remain at idle. Pulling further on the control lever will increase the rpm up to a maximum of wide open throttle (WOT). 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 44: Cautions During Operation

    Carefully select engine mounts and throttle position (maximum engine speed propellers when you design Yanmar position), exceeding the continuous rated Marine engine applications. output engine speed. Operate the engine at...
  • Page 45 . NOTICE: NEVER turn off the battery switch (if equipped) or short the battery cables during operation. Damage to the electric system will result. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 46: Shutting Down The Engine

    CAUTION! If seawater is left inside of the engine, it may freeze and damage parts of the cooling system when the ambient temperature is below 0C (32F). 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 47: Checking The Engine After Operation

    Engine in Long-Term Storage on page return the stop lever to the former position. • At temperatures below 0C (32F), drain seawater system and connect the engine heater (if equipped). 0002063 Figure 7 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 48 ENGINE OPERATION This Page Intentionally Left Blank 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 49: Periodic Maintenance

    ALWAYS use the engine lifting eyes when lifting the engine. Additional equipment is necessary to lift the marine engine and marine gear together. ALWAYS use lifting equipment with sufficient capacity to lift the marine engine. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 50 Any alterations to the welding point. this engine may void its warranty. Always • NEVER connect the weld clamp to the use Yanmar genuine replacement parts. engine or in a manner which would allow current to pass through a mounting bracket.

  • Page 51: Precautions

    WARNING! NEVER block windows, Yanmar Replacement Parts vents, or other means of ventilation if Yanmar recommends that you use genuine the engine is operating in an enclosed Yanmar parts when replacement parts are area. All internal combustion engines needed. Genuine replacement parts help create carbon monoxide gas during ensure long engine life.

  • Page 52: Epa Installation Requirements - Usa Only

    5.1 ± 0.5 9.2 ± 1.0 14.3 ± 1.0 23.5 ± 1.0 lb-ft 8.0 ± 0.7 19.0 ± 2.1 37 ± 3.6 66.0 ± 7.2 103 ± 7.2 170 ± 7.2 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 53: Periodic Maintenance Schedule

    ●. must be inspected and the procedure for doing so for each interval. ◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor System Item Periodic Maintenance Interval...
  • Page 54 PERIODIC MAINTENANCE ◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor System Item Periodic Maintenance Interval Daily Every 50 Every 250 Every 500 Every 1000 Every 2000 (See Daily hours or hours or hours or...

  • Page 55: Inspection And Maintenance Of Epa Emission-Related Parts

    Check the electronic engine control unit (ECU) and its associated sensors and actuators Note: The inspection and maintenance items shown above should be performed at your Yanmar Marine dealer or distributor. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 56: Periodic Maintenance Procedures

    Before you head out for the day, make sure supply. See Drain the Fuel Tank on page the Yanmar engine is in good operating condition. CAUTION! It is important to CAUTION! If any problem is noted...

  • Page 57: After Initial 50 Hours Of Operation

    (Figure 1, (2)). check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar Marine dealer or distributor repair any damage. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 58 CAUTION! Be careful not to get any oil hand until the seal touches. on the V-belt. Oil on the belt causes slipping and stretching. Replace the belt if it is damaged. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 59: Every 50 Hours Of Operation

    Vapors knowledge and techniques. See your from the rag are flammable and authorized Yanmar Marine dealer or explosive. Wipe up any spills distributor to adjust the propeller shaft immediately. Wear eye protection. The alignment.
  • Page 60 ALWAYS use a piece of wood or inside. Dispose of the collected water cardboard. Have your authorized and dirt properly. NOTICE: ALWAYS be Yanmar Marine dealer or distributor environmentally responsible. repair any damage. Drain the Fuel Filter / Water Separator...
  • Page 61 If the power is also used for inboard lighting or other purposes, the generating and charging capacities may be insufficient. In such cases, see your authorized Yanmar Marine dealer or distributor. 0002388 Figure 5 6LY3 LDC Operation Manual...
  • Page 62 Loosen the adjuster bolt (Figure 6, (2)) and move the alternator (Figure 6, (3)). Remove belt from pulleys. 4. Install new belt per routing (Figure 6) and adjust the tension as shown in Step 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 63: Every 250 Hours Of Operation

    2. Illuminate the inside of the seawater and techniques. See your authorized pump with a flashlight and inspect. Yanmar Marine dealer or distributor to check 3. If any of the following problems are the injection spray condition. found, disassembly and maintenance...
  • Page 64 1. Take off the clamp and remove the muffler. 2. Clean the element with a neutral detergent. 0002080 3. Reassemble after the muffler is Figure 7 completely dry. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 65 This should be done only by a trained and specifications. qualified technician. See your authorized NOTICE: NEVER mix different types and / Yanmar Marine dealer or distributor to flush or colors of coolants. the aftercooler. Check the Wiring Connectors Discard old coolant in an approved manner according to environmental laws.

  • Page 66: Every 500 Hours Of Operation

    Check the Fuel Injector Spray Impeller Pattern Replace the used seawater pump impeller Adjustment is necessary to obtain the periodically. See your authorized Yanmar optimal fuel injection to ensure the best Marine dealer or distributor. possible engine performance. Adjust the Propeller Shaft Alignment This inspection requires specialized knowledge and techniques.

  • Page 67: Every 2000 Hours Of Operation

    See your authorized Yanmar Replace Flexible Engine Mounts Marine dealer or distributor to overhaul and check the fuel feed pump. Be sure to replace the Yanmar flexible engine mounts every 1000 hours or 4 years, Clean Engine Oil Cooler whichever comes first.

  • Page 68: Epa Requirements

    (ECU) cover plate aftercooler, freshwater pump, freshwater (Figure 9). cooler, thermostat, etc. See your authorized Yanmar Marine dealer or distributor to clean the seawater and engine coolant systems. Replace Rubber Fuel Hoses Rubberized fuel hoses tend to dry out and become brittle after 2000 hours or 2 years of engine operation, whichever comes first.

  • Page 69: Conditions To Ensure Compliance With Epa Emission Standards

    The warranty period is determined by the age of the engine or the number of • Diesel fuel oil: ASTM D975 No. 1-D or No. hours of operation. See Yanmar Co., Ltd. 2-D, or equivalent (minimum of cetane No. Limited Emission Control System Warranty - USA Only on page 77.
  • Page 70 PERIODIC MAINTENANCE This Page Intentionally Left Blank 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 71: Troubleshooting

    Identify the cause and repair. ON position, see your authorized Is the exhaust color normal? Yanmar Marine dealer or distributor for service before operating the engine. • The continuous emission of black exhaust smoke indicates engine overloading. This CAUTION! If any indicator illuminates shortens the engineʼs life and should be...

  • Page 72: Troubleshooting Information

    Troubleshooting Chart or see Is there sufficient fuel in the fuel tank? your authorized Yanmar Marine dealer or • Refill fuel in advance to avoid running out distributor. of fuel. If the tank runs out of fuel, bleed the Supply the authorized Yanmar Marine fuel system.

  • Page 73: Troubleshooting Chart

    • Poor fuel quality. • Replace with fresh fuel. — Start Black Smoke on Accel- • Propeller too large. • Replace with correct — eration • Hull bottom dirty. size. • Clean hull bottom. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 74 TROUBLESHOOTING This Page Intentionally Left Blank 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 75: Long-Term Storage

    2. Loosen the six bolts attaching the side cover of the seawater pump, remove the cover and drain the water from inside. Retighten the bolts when finished. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 76: Returning The Engine To Service

    6. Waterproof the engine room to prevent rain and seawater from entering. 7. During long-term storage, charge the battery once a month to compensate for the battery’s self-discharge. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 77: Specifications

    Liquid cooling with heat exchanger Normal Operating Temperature Range 71° to 81°C (160° to 190°F) Lubrication System Complete enclosed forced lubrication Normal Oil Pressure Range 4.0 to 5.0 bar (58 to 73 psi) 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 78 4. The “Total Engine Lubricating Oil Capacity” includes oil in oil pan, channels, coolers and filter. 5. The “Effective Engine Lubricating Oil Capacity” indicates the difference in maximum scale of the dipstick and minimum scale. 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 79: Wiring Diagrams

    SPECIFICATIONS Wiring Diagrams Wiring Diagram - 12 V 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 80 SPECIFICATIONS Wiring Diagram - 24 V (Optional) Starter 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 81 SPECIFICATIONS Wiring Harness - Pin Location for 24 V (Optional) 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 82 SPECIFICATIONS This Page Intentionally Left Blank 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 83: Epa Warranty Usa Only

    SYSTEM WARRANTY - USA ONLY The following EPA Warranty only applies to engines built on or after January 01, 2006 and labeled with the proper nameplate (Figure 1). (119578-07701) 0006536 Figure 1 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

  • Page 84: Your Warranty Rights And Obligations

    STATES EPA 40 CFR 94 AND SOLD BY replacement of emission control systems YANMAR THAT ARE INSTALLED IN are Yanmar parts. The owner may elect to VESSELS FLAGGED OR REGISTERED IN have maintenance, replacement or repair of THE UNITED STATES.

  • Page 85: Warranty Coverage

    Yanmar Marine dealer or distributor as soon delivered by Yanmar to the original retail as a problem exists.

  • Page 86: 6Ly3 Ldc Operation Manual

    EPA WARRANTY USA ONLY Maintenance Log Date Operating Maintenance Performed Dealer Name Stamp or Signa- Hours ture 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 87 EPA WARRANTY USA ONLY Date Operating Maintenance Performed Dealer Name Stamp or Signa- Hours ture 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...
  • Page 88 EPA WARRANTY USA ONLY This Page Intentionally Left Blank 6LY3 LDC Operation Manual © 2008 Yanmar Marine International...

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