Yanmar 6LY3 series Operation Manual
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Yanmar 6LY3 series Operation Manual

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6LY3
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OPERATION MANUAL
6LY3 Operation Manual
P/N: 0A1957-G0000
MARINE
ENGINES

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Summary of Contents for Yanmar 6LY3 series

  • Page 1 Back 6LY3 series OPERATION MANUAL 6LY3 Operation Manual P/N: 0A1957-G0000 MARINE ENGINES...
  • Page 2 No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of Yanmar Marine International.

  • Page 3: Introduction

    Back INTRODUCTION 6LY3 Operation Manual Welcome to the world of Yanmar Marine! • Make sure this manual is transferred to Yanmar Marine offers engines, drive subsequent owners. This manual should systems and accessories for all types of be considered a permanent part of the boats, from runabouts to sailboats, and engine and remain with it.

  • Page 4: Record Of Ownership

    Back 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 Operation Manual...

  • Page 5: Table Of Contents

    Safety Precautions ............. 2 Before You Operate..........2 During Operation and Maintenance..... 3 Product Overview ............21 Yanmar 6LY3 Features and Applications....21 Component Identification ........22 Operation Side ..........22 Non-Operation Side ........23 Location of Labels ..........24 Nameplate..............
  • Page 6 Keep a Log of Engine Hours and Daily Checks . 91 Yanmar Replacement Parts ....... 91 Tools Required........... 91 Ask Your Authorized Yanmar Marine Dealer for Help............... 91 Required EPA Maintenance - USA Only.... 92 EPA Installation Requirements - USA Only ..92 Tightening Fasteners .........
  • Page 7 Back TABLE OF CONTENTS Periodic Maintenance Schedule ......93 Inspection and Maintenance of EPA Emission-Related Parts....... 95 Periodic Maintenance Procedures..... 96 After Initial 50 Hours of Operation....96 Replace Engine Oil and Engine Oil Filter ..........96 Check the Electronic Control System Operation .........
  • Page 8 Back TABLE OF CONTENTS Every 1000 Hours of Operation ....110 Check the Fuel Injector Spray Pattern..........110 Clean and Check the Seawater Passages ..........110 Replace Alternator Belt ....... 110 Adjust Intake / Exhaust Valve Clearance..........110 Replace Flexible Engine Mounts..110 Every 2000 Hours of Operation ....

  • Page 9: Table Of Contents

    Back SAFETY 6LY3 Operation Manual Yanmar considers safety of great DANGER importance and recommends that anyone who comes into close contact with its Danger (the word “DANGER” is products, such as those who install, in white letters with a red operate, maintain or service Yanmar rectangle behind it) –...

  • Page 10: Safety Precautions

    0000001enMarine maintenance procedures. • Safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar marine dealer or distributor for additional training. 0000002enMarine 6LY3 Operation Manual...

  • Page 11: During Operation And Maintenance

    Back SAFETY During Operation and DANGER Maintenance DANGER SCALD HAZARD! EXPLOSION HAZARD! • NEVER remove the fill cap if • Keep the area around the the engine is hot. Steam and battery well-ventilated. While hot engine coolant will spurt the engine is running or the out and seriously burn you.
  • Page 12 Back SAFETY DANGER DANGER FIRE AND EXPLOSION FIRE AND EXPLOSION HAZARD! HAZARD! • Diesel fuel is flammable and • Diesel fuel is flammable and explosive under certain explosive under certain conditions. conditions. • NEVER remove the fuel cap • Only fill the fuel tank with with the engine running.
  • Page 13 Back SAFETY DANGER DANGER FIRE AND EXPLOSION EXPLOSION HAZARD! HAZARD! • NEVER check the remaining • Diesel fuel is extremely battery charge by shorting out flammable and explosive under the terminals. This will result in certain conditions. a spark and may cause an •...
  • Page 14 Back SAFETY DANGER DANGER CRUSH HAZARD! FIRE AND EXPLOSION HAZARD! • When you need to transport an • Diesel fuel is extremely engine for repair have a helper flammable and explosive under assist you attach it to a hoist certain conditions. and load it on a truck.
  • Page 15 Back SAFETY WARNING WARNING EXHAUST HAZARD! SEVER HAZARD! • NEVER operate the engine in • Keep hands and other body an enclosed area such as a parts away from garage, tunnel, underground moving / rotating parts such as room, manhole or ship’s hold the flywheel or PTO shaft.
  • Page 16 Back SAFETY WARNING WARNING ALCOHOL AND DRUG HAZARD! EXPOSURE HAZARD! • NEVER operate the engine • Wear personal protective while you are under the equipment such as gloves, influence of alcohol or drugs. work shoes, eye and hearing • NEVER operate the engine protection as required by the when you are feeling ill.
  • Page 17 ALWAYS use NEVER allow battery fluid to a piece of wood or cardboard. come in contact with clothing, Have your authorized Yanmar skin or eyes. Severe burns marine dealer or distributor could result. ALWAYS wear repair the damage.
  • Page 18 Back SAFETY WARNING WARNING ENTANGLEMENT SHOCK HAZARD! HAZARD! • Turn off the battery switch (if • Stop the engine before you equipped) or disconnect the begin to service it. negative battery cable before • NEVER leave the key in the key servicing the electrical system.
  • Page 19 Back SAFETY WARNING WARNING BURN HAZARD! FIRE HAZARD! • If you must drain the engine oil • Undersized wiring systems can while it is still hot, stay clear of cause an electrical fire. the hot engine oil to avoid • Failure to comply could result being burned.
  • Page 20 0000003en maintenance instructions. 0000018en CAUTION • Only use diesel fuels CAUTION recommended by Yanmar for If any indicator illuminates the best engine performance, during engine operation, stop to prevent engine damage and the engine immediately. to comply with EPA warranty Determine the cause and repair requirements.
  • Page 21 START position for longer than be operated in either 15 seconds or the starter motor temperature extreme. will overheat. • See your authorized Yanmar 0000007en marine dealer or distributor if you need to operate the engine at high altitudes. At high...
  • Page 22 CAUTION Carefully clean the heat For maximum engine life, exchanger cap and the Yanmar recommends that when surrounding area before you shutting the engine down, you remove the cap. allow the engine to idle, without • NEVER mix different types of load, for 5 minutes.
  • Page 23 CAUTION CAUTION Make sure the engine is installed New Engine Break In: on a level surface. If a Yanmar • On the initial engine start-up, Marine Engine is installed at an check for proper engine oil angle that exceeds the...
  • Page 24 ON position, see your • ALWAYS be environmentally authorized Yanmar marine dealer responsible. or distributor for service before operating the engine. • Follow the guidelines of the...
  • Page 25 Carefully select engine mounts and propellers • NEVER operate the engine with when you design Yanmar marine the air cleaner or element(s) engine applications. removed. This may allow foreign material to enter the 0000085en engine and damage it.
  • Page 26 This water could cause seizure of the non-running engine(s). See your authorized Yanmar marine dealer or distributor for a complete explanation of this condition. 0000157en 6LY3 Operation Manual...
  • Page 27 Back SAFETY CAUTION If you have an installation with two or three engines, and only one engine is operating, the water pickup (thru-hull) of the non-running engine(s) should be closed. This will prevent water from being forced past the seawater pump and eventually finding its way into the engine.
  • Page 28 Back SAFETY This Page Intentionally Left Blank 6LY3 Operation Manual...

  • Page 29: Product Overview

    See operate at 100-200 rpm above maximum Yanmar's local subsidiary in your region or rpm to allow for some added weight and your authorized Yanmar marine dealer or hull resistance. Failure to do so can lead to distributor.

  • Page 30: Component Identification

    Back PRODUCT OVERVIEW COMPONENT IDENTIFICATION Operation Side 0002020 1. Oil Fill Cap 6. Lube Oil Filter 2. Coolant Fill Cap 7. Inter-Cooler 3. Electronic Control Unit Cover Plate 8. Flywheel 4. Fuel Injection Pump 9. Air Intake Silencer 5. Lube Oil Cooler 10.

  • Page 31: Non-Operation Side

    Back PRODUCT OVERVIEW Non-Operation Side 0002021 1. Coolant Tank (Exhaust Manifold) 5. Alternator 2. Dipstick 6. V-Belt 3. Fresh Water Cooler 7. Fuel Filter 4. Seawater Pump 8. Fresh Water Pump Figure 2 6LY3 Operation Manual...

  • Page 32: Location Of Labels

    Back PRODUCT OVERVIEW LOCATION OF LABELS 128296-07300 Figure 3 shows the location of regulatory and safety labels on Yanmar 6LY3 series engines. Please replace if damaged or lost. 120324-07240 0002079 128296-07260 Warning Labels Description Part Number Hot Surface 128296-07300 Lifting Precautions...

  • Page 33: Nameplate

    Check the engine model, output, rpm and serial number on the nameplate. MODEL CONT. RATING Kw SPEED OF PROP. SHAFT MAX. OUT PUT Kw ENGINE NO. YANMAR DIESEL ENGINE YANMAR CO., LTD. MADE IN JAPAN 0002019 Figure 4 6LY3 Operation Manual...

  • Page 34: Function Of Major Components

    Back PRODUCT OVERVIEW FUNCTION OF MAJOR COMPONENTS Name of part Function Removes dirt and water from fuel. Drain the filter periodically. The element (filter) Fuel Filter should be replaced periodically. See Replace the Fuel Filter Element on page 106. Fuel Pumps fuel from tank to the fuel injection pump.

  • Page 35: Electronic Control System (Ecs)

    Module and the Control Head, which are connected by the wire harness to the Engine (electronic governor and marine gear) for remote control operation. See Yanmar Electronic Control System Operation Manual for LY3 Engines for a more complete description of the electronic control system (ECS).

  • Page 36: Display

    Port Eng Alarms Alarm Log 061803 17:04 - COM ERROR Y 025 P0120/FEB0 THROTTLE SENSOR WTR TEMP VALUE OUT OF RANGE. 2615 CONTACT YANMAR DISTRIBUTOR X1000 1 1 4 EXIT 0002025 0002023 Figure 6 Figure 8 This screen displays real time engine data Alarm Indicator Functions and alarm indications.
  • Page 37 Back PRODUCT OVERVIEW Rocker Switch Panel 3. Sub-Throttle Control (Figure 9, (3)) In the unlikely event that the throttle The rocker switch panel has the following control fails, the sub-throttle indicator functions. light will flash and the engine speed is 1st Station Panel (Figure 9) controlled the sub-throttle.
  • Page 38 Back PRODUCT OVERVIEW Control Head Shift and Throttle Control Head Button Functions Functions • N (or NEUTRAL) Button – If the Use the two-lever control head associated control head lever is in the (Figure 11, (4)) in the helm station for “Neutral Idle”...
  • Page 39 Back PRODUCT OVERVIEW Control Head Operation Selecting Active Station: SELECT SYNC SELECT SYNC SELECT SYNC 0002030 Figure 13 (a) (Figure 13, (1)) shows a typical inactive station. (b) Press the SELECT button (Figure 13, (2)). The button lights Figure 14 (grayed in (Figure 13)) and the station select light flashes (star Engage:...
  • Page 40 Back PRODUCT OVERVIEW The Split Range Throttle control head (c) If the system is shifted into neutral mode gives you greater throttle sensitivity. while in the Split Range Throttle In Split Range Throttle (SRT), moving an engine mode, the N (Neutral) lamp engine’s control lever all the way to the will come on (steady) to indicate that “Full Forward”...
  • Page 41 Back PRODUCT OVERVIEW Engaging / Disengaging Cruise Disengage: Synchronization Press the SYNC button on the control head. Figure 16 Engage: (a) Disengage any other engine mode being used. (b) Match all engine shift and throttle settings by moving the active port and starboard control head levers to within 10% of each other (Figure 16, (1)) and press the SYNC...
  • Page 42 Back PRODUCT OVERVIEW This Page Intentionally Left Blank 6LY3 Operation Manual...

  • Page 43: Before You Operate

    • Safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar marine dealer or distributor for additional training. 0000002enMarine 6LY3 Operation Manual...

  • Page 44: Fire And Explosion

    Back BEFORE YOU OPERATE DANGER DANGER FIRE AND EXPLOSION HAZARD! • Diesel fuel is flammable and SCALD HAZARD! explosive under certain • NEVER remove the fill cap if conditions. the engine is hot. Steam and • Only fill the fuel tank with hot engine coolant will spurt diesel fuel.
  • Page 45 Back BEFORE YOU OPERATE DANGER DANGER FIRE AND EXPLOSION FIRE AND EXPLOSION HAZARD! HAZARD! • Diesel fuel is extremely • Diesel fuel is extremely flammable and explosive flammable and explosive under certain conditions. under certain conditions. • Be sure to place the diesel fuel •...
  • Page 46 WARNING treatment. • NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar BURN HAZARD! marine dealer or distributor repair the damage. • Keep your hands, and other body parts, away from hot •...
  • Page 47 Back BEFORE YOU OPERATE CAUTION WARNING • Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA warranty BURN HAZARD! requirements. • Wait until the engine cools • Only use clean diesel fuel.

  • Page 48: Diesel Fuel

    • Fuel additives are not recommended. 0000006enTrans Some fuel additives may cause poor engine performance. See your authorized Yanmar marine dealer or DIESEL FUEL distributor for more information. Diesel Fuel Specifications • Ash content not to exceed 0.01% by volume.

  • Page 49: Filling The Fuel Tank

    Back BEFORE YOU OPERATE Diesel Fuel Lines Filling the Fuel Tank Install the lines between the fuel tank and the fuel injection pump. DANGER Be sure to install a drain cock (Figure 1, (6)) at the bottom of the fuel tank to remove water and contaminants.
  • Page 50 • Failure to comply will result in CAUTION death or serious injury. • Only use diesel fuels 0000014en recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA warranty requirements. • Only use clean diesel fuel.

  • Page 51: Bleeding The Fuel System

    Back BEFORE YOU OPERATE Filling the Fuel Tank (Continued) The engine has an automatic air bleed system. Bleeding the fuel system is not 1. Clean the area around the fuel cap. required for normal engine operation. 2. Remove the fuel cap from the fuel tank. The fuel system needs to be bled under 3.

  • Page 52: Engine Oil

    SAE Service Grade Viscosity Chart remove the cap. (Figure 2). • NEVER mix different types of 4. Yanmar does not recommend the engine oil. This may adversely use of engine oil “additives.” affect the lubricating properties of the engine oil.

  • Page 53: Engine Oil Viscosity

    Back BEFORE YOU OPERATE Engine Oil Viscosity Adding Engine Oil 1. Remove the yellow filler port cap SAE 15W40 is the recommended oil (Figure 3, (2)) at the top of the rocker viscosity. arm cover (Figure 3, (1)), and fill with If you operate your engine outside the SAE engine oil.

  • Page 54: Engine Coolant

    Back BEFORE YOU OPERATE ENGINE COOLANT CAUTION DANGER COOLANT HAZARD! • Wear eye protection and SCALD HAZARD! rubber gloves when you • NEVER remove the fill cap if handle Long Life or Extended the engine is hot. Steam and Life engine coolant. If contact hot engine coolant will spurt with the eyes or skin should out and seriously burn you.

  • Page 55: Engine Coolant Specifications

    Back BEFORE YOU OPERATE Engine Coolant Specifications Following the manufacturer’s recommendations. Use the proper LLC Use a Long Life Coolant (LLC) that meets which will not have any adverse effects on or exceeds the following guidelines and the materials (cast iron, aluminum, copper, specifications: etc.) of the engine’s fresh water cooling Note: In the U.S., LLC is required for...
  • Page 56 Back BEFORE YOU OPERATE Filling Heat Exchanger with Engine This procedure is for filling the heat exchanger for the first time or refilling it Coolant after it is flushed. Note that a typical heat exchanger is shown (Figure 4). DANGER 1.
  • Page 57 Back BEFORE YOU OPERATE 4. After filling the heat exchanger, replace fill cap and tighten it firmly (Figure 6, (1)). Failure to do so will cause coolant leakage. To replace the cap, align the tabs (Figure 6, (2)) on the bottom of the cap with the notches on the filler port and turn clockwise 1/3 of a turn.

  • Page 58: Cranking

    Back BEFORE YOU OPERATE CRANKING 6. Turn the start switch to the ON position. 7. Push and hold the start switch for 15 When the engine has not been used for a seconds (cranking). Release the start long period of time, engine oil will not be switch and the engine stops.

  • Page 59: Daily Checks

    DAILY CHECKS CAUTION Before you head out for the day, make It is important to perform daily sure the Yanmar engine is in good checks as listed in the Operation operating condition. Make sure you check Manual. the following items.

  • Page 60: Check Diesel Fuel, Engine Oil, And Engine Coolant Levels

    Checking the Control Head Be sure to check that the control lever moves smoothly before use. If it is hard to operate, see your authorized Yanmar dealer or distributor. Checking the Alarm Indicators When operating the start switch on the...

  • Page 61: Engine Operation

    • Safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar marine dealer or distributor for additional training. 0000002enMarine 6LY3 Operation Manual...

  • Page 62: Engine Operation

    Back ENGINE OPERATION DANGER DANGER EXPLOSION HAZARD! • Keep the area around the SCALD HAZARD! battery well-ventilated. While • NEVER remove the fill cap if the engine is running or the the engine is hot. Steam and battery is charging, hydrogen hot engine coolant will spurt gas is produced which can be out and seriously burn you.
  • Page 63 Back ENGINE OPERATION DANGER DANGER FIRE AND EXPLOSION FIRE AND EXPLOSION HAZARD! HAZARD! • Diesel fuel is flammable and • Diesel fuel is flammable and explosive under certain explosive under certain conditions. conditions. • Only fill the fuel tank with •...
  • Page 64 Back ENGINE OPERATION DANGER DANGER FIRE AND EXPLOSION FIRE AND EXPLOSION HAZARD! HAZARD! • Diesel fuel is extremely • Diesel fuel is flammable and flammable and explosive under explosive under certain certain conditions. conditions. • Be sure to place the diesel fuel •...
  • Page 65 Back ENGINE OPERATION WARNING WARNING EXHAUST HAZARD! SEVER HAZARD! • NEVER operate the engine in • Keep hands and other body an enclosed area such as a parts away from garage, tunnel, underground moving / rotating parts such as room, manhole or ship’s hold the flywheel or PTO shaft.
  • Page 66 Back ENGINE OPERATION WARNING WARNING ALCOHOL AND DRUG HAZARD! EXPOSURE HAZARD! • NEVER operate the engine • Wear personal protective while you are under the equipment such as gloves, influence of alcohol or drugs. work shoes, eye and hearing • NEVER operate the engine protection as required by the when you are feeling ill.
  • Page 67 • NEVER check for a fuel leak in death or serious injury. with your hands. ALWAYS use 0000015en a piece of wood or cardboard. Have your authorized Yanmar marine dealer or distributor WARNING repair the damage. • Failure to comply could result in death or serious injury.
  • Page 68 Back ENGINE OPERATION CAUTION CAUTION • Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA warranty requirements. COOLANT HAZARD! • Only use clean diesel fuel. • Wear eye protection and •...
  • Page 69 Back ENGINE OPERATION CAUTION CAUTION NEVER hold the key in the The illustrations and START position for longer than descriptions of optional 15 seconds or the starter motor equipment in this manual, such will overheat. as the operator’s console, are for a typical engine installation.
  • Page 70 0000152en distributor if the engine will be operated in either temperature extreme. • See your authorized Yanmar marine dealer or distributor if you need to operate the engine at high altitudes. At high altitudes the engine will lose...
  • Page 71 Carefully select engine. If you observe black engine mounts and propellers smoke or movement of the when you design Yanmar marine throttle does not increase engine engine applications. RPM, you are overloading the engine that is running.

  • Page 72: Starting The Engine

    Back ENGINE OPERATION STARTING THE ENGINE Before Starting the Engine 1. Open the seacock. Start 2. Open the fuel tank cock. Sub throttle active Eng ON Emergency 3. Set the control lever on the control Stop head (Figure 1, (2)) in N (NEUTRAL) Sub throttle (Figure 1, (1)) position.
  • Page 73 Back ENGINE OPERATION Before pressing the start switch again, 3. Check that exhaust color, engine confirm that the engine has stopped vibrations, and sound are normal. completely. If the starter motor is operated 4. When there are no problems, keep the before the engine has completely stopped, engine at low speed to send engine oil the starter motor pinion gear will be...

  • Page 74: Shifting

    Back ENGINE OPERATION Shifting WARNING SUDDEN MOVEMENT HAZARD! The boat will start to move when the marine gear is engaged: • Ensure the boat is clear of all obstacles forward and aft. • Quickly shift to the FORWARD position then back to the NEUTRAL position.

  • Page 75: Cautions During Operation

    This water could to overheat or cause excess cause seizure of the non-running carbon buildup which may engine(s). See your authorized shorten the engine's life. Yanmar marine dealer or distributor for a complete 0000150en explanation of this condition. 0000157en CAUTION...
  • Page 76 • During the break-in period, discomfort. Carefully select carefully observe the engine engine mounts and propellers oil pressure and engine when you design Yanmar marine temperature. engine applications. • During the break-in period, 0000085en check the engine oil and coolant levels frequently.
  • Page 77 Back ENGINE OPERATION 4. Alarm buzzer sounds during operation. This will generate higher exhaust temperatures, which will help clean out hard carbon deposits, maintaining CAUTION engine performance and prolonging the If any alarm indicator with life of the engine. audible alarm sound appears on the display during engine CAUTION operation, stop the engine...

  • Page 78: Shutting Down The Engine

    Sub throttle active Eng ON Emergency Stop For maximum engine life, Sub throttle Yanmar recommends that when shutting the engine down, you 0002062 allow the engine to idle, without Figure 6 load, for 5 minutes. This will allow the engine components...
  • Page 79 Back ENGINE OPERATION IMPORTANT WARNING Use this switch only in an emergency. Under normal circumstances, use the OFF, ON, START switch (Figure 6, (1)) to stop the engine. Note: Restarting the engine after using SEVER HAZARD! the emergency stop may be •...
  • Page 80 Back ENGINE OPERATION This Page Intentionally Left Blank 6LY3 Operation Manual...

  • Page 81: Periodic Maintenance

    • Safety signs and labels are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar marine dealer or distributor for additional training. 0000002enMarine 6LY3 Operation Manual...

  • Page 82: During Operation And Maintenance

    Back PERIODIC MAINTENANCE During Operation and DANGER Maintenance DANGER SCALD HAZARD! EXPLOSION HAZARD! • NEVER remove the fill cap if • Keep the area around the the engine is hot. Steam and battery well-ventilated. While hot engine coolant will spurt the engine is running or the out and seriously burn you.
  • Page 83 Back PERIODIC MAINTENANCE DANGER DANGER FIRE AND EXPLOSION FIRE AND EXPLOSION HAZARD! HAZARD! • Diesel fuel is flammable and • Diesel fuel is flammable and explosive under certain explosive under certain conditions. conditions. • When you remove any fuel • NEVER use diesel fuel as a system component to perform cleaning agent.
  • Page 84 Back PERIODIC MAINTENANCE DANGER DANGER FIRE AND EXPLOSION FIRE AND EXPLOSION HAZARD! HAZARD! • Diesel fuel is flammable and • Only use the key switch to start explosive under certain the engine. conditions. • NEVER jump start the engine. • Only fill the fuel tank with Sparks caused by shorting the diesel fuel.
  • Page 85 Back PERIODIC MAINTENANCE DANGER DANGER FIRE AND EXPLOSION EXPLOSION HAZARD! HAZARD! • NEVER check the remaining • Diesel fuel is extremely battery charge by shorting out flammable and explosive under the terminals. This will result in certain conditions. a spark and may cause an •...
  • Page 86 Back PERIODIC MAINTENANCE DANGER WARNING FIRE AND EXPLOSION SEVER HAZARD! HAZARD! • Keep hands and other body • Diesel fuel is flammable and parts away from explosive under certain moving / rotating parts such as conditions. the flywheel or PTO shaft. •...
  • Page 87 Back PERIODIC MAINTENANCE WARNING WARNING EXHAUST HAZARD! ALCOHOL AND DRUG • NEVER operate the engine in HAZARD! an enclosed area such as a • NEVER operate the engine garage, tunnel, underground while you are under the room, manhole or ship’s hold influence of alcohol or drugs.
  • Page 88 Back PERIODIC MAINTENANCE WARNING WARNING SUDDEN MOVEMENT HAZARD! • Be sure the boat is in open water away from other boats, docks, and other obstructions before increasing rpm. EXPOSURE HAZARD! • Failure to comply could result • Wear personal protective in death or serious injury.
  • Page 89 • NEVER check for a fuel leak in death or serious injury. with your hands. ALWAYS use a piece of wood or cardboard. 0000009en Have your authorized Yanmar marine dealer or distributor repair the damage. • Failure to comply could result in death or serious injury.
  • Page 90 Back PERIODIC MAINTENANCE WARNING WARNING ENTANGLEMENT BURN HAZARD! HAZARD! • If you must drain the engine oil • Stop the engine before you while it is still hot, stay clear of begin to service it. the hot engine oil to avoid being burned.
  • Page 91 Back PERIODIC MAINTENANCE WARNING CAUTION BURN HAZARD! • Keep your hands, and other COOLANT HAZARD! body parts, away from hot engine surfaces such as the • Wear eye protection and muffler, exhaust pipe, rubber gloves when you turbocharger (if equipped) and handle Long Life or Extended engine block during operation Life engine coolant.
  • Page 92 Back PERIODIC MAINTENANCE CAUTION CAUTION • Only use diesel fuels The illustrations and recommended by Yanmar for descriptions of optional the best engine performance, equipment in this manual, such to prevent engine damage and as the operator’s console, are for to comply with EPA warranty a typical engine installation.
  • Page 93 • See your authorized Yanmar • Prevent dirt and debris from marine dealer or distributor if contaminating engine oil. you need to operate the engine Carefully clean the oil at high altitudes.
  • Page 94 CAUTION • NEVER overfill the engine with Make sure the engine is installed engine oil. on a level surface. If a Yanmar Marine Engine is installed at an • ALWAYS keep the oil level angle that exceeds the between upper and lower lines specifications stated in the on the oil cap / dipstick.
  • Page 95 ON position, see your • ALWAYS be environmentally authorized Yanmar marine dealer responsible. or distributor for service before operating the engine. • Follow the guidelines of the...
  • Page 96 Carefully select engine mounts and propellers • NEVER operate the engine with when you design Yanmar marine the air cleaner or element(s) engine applications. removed. This may allow foreign material to enter the 0000085en engine and damage it.
  • Page 97 This water could cause seizure of the non-running engine(s). See your authorized Yanmar marine dealer or distributor for a complete explanation of this condition. 0000157en 6LY3 Operation Manual...

  • Page 98: Precautions

    Back PERIODIC MAINTENANCE PRECAUTIONS CAUTION If you have an installation with The Importance of Periodic two or three engines, and only Maintenance one engine is operating, the Engine deterioration and wear occurs in water pickup (thru-hull) of the proportion to length of time the engine has non-running engine(s) should be been in service and the conditions the closed.

  • Page 99: Performing Periodic Maintenance

    Accumulation of Yanmar Replacement Parts this gas within an enclosure Yanmar recommends that you use genuine could cause illness or even Yanmar parts when replacement parts are death. needed. Genuine replacement parts help •...

  • Page 100: Required Epa Maintenance - Usa Only

    Back PERIODIC MAINTENANCE Required EPA Maintenance - Tightening Fasteners USA Only Use the correct amount of torque when you tighten fasteners on the machine. To maintain optimum engine performance Applying excessive torque may damage and compliance with the Environmental the fastener or component and not enough Protection Agency (EPA) Regulations, it is torque may cause a leak or component essential that you follow the Periodic...

  • Page 101: Periodic Maintenance Schedule

    : Check : Replace : Contact your authorized Yanmar marine dealer or distributor Periodic Maintenance Interval Every Every 250 Every 500 Every Every 50 hrs.
  • Page 102 Back PERIODIC MAINTENANCE : Check : Replace : Contact your authorized Yanmar marine dealer or distributor Periodic Maintenance Interval Every Every 250 Every 500 Every Every 50 hrs. or hrs. or one hrs. or 2 1000 hrs. 2000 hrs. System...

  • Page 103: Inspection And Maintenance Of Epa Emission-Related Parts

    Check fuel injection pump adjustment 3000 hours Check turbocharger adjustment Check electronic engine control unit (ECU) and its associated sensors and actuators Note: The inspection and maintenance items shown above to be performed at your Yanmar dealer or distributor. 6LY3 Operation Manual...

  • Page 104: Periodic Maintenance Procedures

    Back PERIODIC MAINTENANCE PERIODIC MAINTENANCE CAUTION PROCEDURES • Only use the engine oil specified. Other engine oils After Initial 50 Hours of may affect warranty coverage, Operation cause internal engine components to seize, or shorten engine life. Perform the following maintenance after the initial 50 hours of operation.
  • Page 105 Back PERIODIC MAINTENANCE Turn the bypass filter (Figure 1, (3)) an CAUTION additional one turn clockwise with the filter wrench. • ALWAYS be environmentally responsible. • Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant.

  • Page 106: Check The Electronic Control System Operation

    Check for cracks, abrasions, and damaged, loose or corroded connectors. If there is unusual noise and / or vibration, this maintenance requires specialized knowledge and techniques. See your authorized Yanmar marine dealer or distributor to adjust the propeller shaft alignment. 6LY3 Operation Manual...

  • Page 107: Every 50 Hours Of Operation

    Back PERIODIC MAINTENANCE Drain Fuel Filter and Every 50 Hours of Operation Fuel Filter / Water Separator Perform the following maintenance every DANGER 50 hours or one month of operation, whichever comes first. • Drain Fuel Filter and Fuel Filter / Water Separator FIRE AND EXPLOSION •...
  • Page 108 Back PERIODIC MAINTENANCE Drain the Fuel Filter CAUTION If the fuel filter / water separator is positioned higher than the fuel level in the fuel tank, water may not drip out when the fuel filter / water separator drain cock is opened.

  • Page 109: Check The Battery

    Back PERIODIC MAINTENANCE 4. When a fuel filter or fuel filter / water WARNING separator is provided in the hull in addition to those installed on the engine, also drain and clean them or replace the element. 5. After reassembly of the fuel filter / water BURN HAZARD! separator, be sure to bleed air from the fuel system.
  • Page 110 0000013en other purposes, the generating and charging capacities may be insufficient. In such cases, see your authorized Yanmar marine dealer or distributor. 0002388 Figure 4 1. Do not operate engine if battery has insufficient battery fluid as the battery will be destroyed.

  • Page 111: Adjust Alternator V-Belt Tension

    Back PERIODIC MAINTENANCE Adjust Alternator V-Belt Tension When there is not enough tension in the V-belt, it will slip and the fresh water pump will fail to supply coolant. Engine overheating and seizure will result. When there is too much tension in the V-belt, the belt will become damaged more quickly and the fresh water pump bearing may be damaged.

  • Page 112: Every 250 Hours Of Operation

    • Replace the Anode and techniques. See your authorized • Clean the Air Intake Silencer Yanmar marine dealer or distributor to adjust the intake / exhaust valve clearance. • Clean the Exhaust / Water Mixing Elbow •...

  • Page 113: Drain The Fuel Tank

    Back PERIODIC MAINTENANCE Drain the Fuel Tank CAUTION DANGER • ALWAYS be environmentally FIRE AND EXPLOSION responsible. HAZARD! • Follow the guidelines of the • Diesel fuel is flammable and EPA or other governmental explosive under certain agencies for the proper conditions.

  • Page 114: Replace The Fuel Filter Element

    Back PERIODIC MAINTENANCE Replace the Fuel Filter Element Replace the Engine Oil (Crankcase) When the engine is operated on light diesel oil, replace the fuel filter element See Replace Engine Oil and Engine Oil every 250 hours or one year of operation. Filter on page 96.

  • Page 115: Replace The Anode

    Replace the anode when it has decreased the seawater pump are necessary, see to less than 1/2 of the original volume. If your Yanmar dealer or distributor. replacement of anode is neglected and Note: The seawater pump turns in the...

  • Page 116: Clean The Exhaust / Water Mixing Elbow

    See your authorized mixing elbow. Yanmar marine dealer or distributor to 2. Repair the crack or damage of the tighten major nuts and bolts. mixing elbow by welding, or replace if necessary.

  • Page 117: Replace Engine Coolant

    • NEVER mix different types and / or Impeller colors of coolants. Replace the used seawater pump impeller Discard old coolant in an approved manner periodically. See your authorized Yanmar according to environmental laws. marine dealer or distributor. Adjust the Propeller Shaft Alignment The rubber tension of the flexible engine mounts is lost after many hours' use.

  • Page 118: Every 1000 Hours Of Operation

    Replace Flexible Engine Mounts This inspection requires specialized Be sure to replace the Yanmar flexible knowledge and techniques. See your engine mounts every 1000 hours or 4 authorized Yanmar marine dealer or years, whichever comes first.

  • Page 119: Every 2000 Hours Of Operation

    Perform the following maintenance every cooler, thermostat, etc. 2000 hours or eight years of operation, See your authorized Yanmar marine dealer whichever comes first. or distributor to clean the seawater and • Overhaul and Check Fuel Feed Pump engine coolant systems.

  • Page 120: Epa Requirements

    Back PERIODIC MAINTENANCE EPA REQUIREMENTS The EPA emission regulation is applicable The following are the conditions that must only in USA. be met in order to ensure that the emissions during operation meet the EPA EPA Certification Plates standards. Be sure to follow these: The engine has the EPA Certification The operating conditions should be as Plates (emission control label and...

  • Page 121: Inspection And Maintenance

    The warranty period is determined by the age of the engine or the number of hours of operation. See Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only on page 123.
  • Page 122 Back PERIODIC MAINTENANCE This Page Intentionally Left Blank 6LY3 Operation Manual...

  • Page 123: Troubleshooting

    ON position, see your immediately. Determine the authorized Yanmar marine dealer cause and repair the problem or distributor for service before before you continue to operate operating the engine.

  • Page 124: Troubleshooting Chart

    • Contamination inside cooling • See your authorized system. Yanmar marine dealer — or distributor. Do not operate the engine if alarm devices are not repaired. Serious accidents may Faulty Warning Devices result if difficulties are not spotted due to faulty alarm lamps.

  • Page 125: Troubleshooting Information

    TROUBLESHOOTING TROUBLESHOOTING INFORMATION If your engine does not operate properly, refer to the troubleshooting chart or see your authorized Yanmar marine dealer or distributor. Supply the authorized Yanmar marine dealer or distributor with the following information: • Model name and serial number of your engine •...
  • Page 126 Back TROUBLESHOOTING This Page Intentionally Left Blank 6LY3 Operation Manual...

  • Page 127: Long-Term Storage

    Back LONG-TERM STORAGE 6LY3 Operation Manual BEFORE YOU PLACE THE CAUTION ENGINE IN LONG-TERM If seawater is left inside of the STORAGE engine, it may freeze and damage parts of the cooling In cold temperatures or before long-term system when the ambient storage, be sure to drain the seawater from temperature is below 0°C (32°F).

  • Page 128: Returning The Engine To Service

    Back LONG-TERM STORAGE 1. Loosen the seawater drain cocks Before placing the engine in storage, (Figure 1, (1)) and (Figure 2, (1)) and perform the following: drain the seawater. 1. Clean the outside of the engine wiping off any dust or oil. 2.

  • Page 129: Specifications

    Back SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS Engine Model 6LY3-ETP 6LY3-STP 6LY3-UTP Pleasure Use Type Vertical water-cooled, 4-cycle diesel engine Aspiration Turbocharger with Aftercooler Combustion System Direct injection Number of Cylinders Bore x Stroke 105.9 × 110 mm (4.17 × 4.33 in) Displacement 5.813 L (6.14 qt) 3198 min (rpm)
  • Page 130 Back SPECIFICATIONS Engine Model 6LY3-ETP 6LY3-STP 6LY3-UTP Type Electric Starting System Starting Motor DC 12V - 3kW AC Generator 12V - 80A Model RHC7W (IHI made) Turbocharger Type Water cooled Overall Length 1300.4 mm (51.2 in) Engine Dimension Overall Width 801.3 mm (31.5 in) Overall Height 776.6 mm (30.6 in)

  • Page 131: Epa Warranty Usa Only

    Back EPA WARRANTY USA ONLY YANMAR CO., LTD. LIMITED EMISSION CONTROL 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). 0003493...
  • Page 132 UNITED STATES EPA 40 CFR 94 AND replacement of emission control systems SOLD BY YANMAR THAT ARE are Yanmar parts. The owner may elect to INSTALLED IN VESSELS FLAGGED OR have maintenance, replacement or repair REGISTERED IN THE UNITED STATES.
  • Page 133 Yanmar dealer or distributor as delivered by Yanmar to the original retail soon as a problem exists. purchaser. Such components may include the following: Customer Assistance: 1.
  • Page 134 Back President, Yanmar Marine Int’l...
  • Page 135 Back President, Yanmar Marine Int’l...
  • Page 136 Back EPA WARRANTY USA ONLY This Page Intentionally Left Blank...

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