Yanmar 6LY3 series Manuals

Manuals and User Guides for Yanmar 6LY3 series. We have 4 Yanmar 6LY3 series manuals available for free PDF download: Service Manual, Operation Manual, Technical Manual

Yanmar 6LY3 series Service Manual (390 pages)

Brand: Yanmar | Category: Engine | Size: 70.81 MB

Section 3 General Service Information

15
- Location of Safety Decals
  13
- Table of Contents
  15
- Safety Precautions
  17
- 6LY3-ETP Exterior Views
  18
  - Operation Side
    18
  - Non-Operation Side
    18
- Diesel Fuel
  20
  - Diesel Fuel Specifications
    20
- Engine Oil
  22
  - Engine Oil Specifications
    22
- Marine Gear Oil
  22
- Engine Coolant
  23
  - Handling of Coolant
    23
- Engine Outline Drawings
  24
  - 6Ly3-Etp / Stp / Utp (Yt-15 Mount)
    24
  - 6Ly3-Etp
    25
- Exhaust Gas Emission Regulations
  26
- Engine Nameplate
  28
- Reduction and Reversing Gear
  28
- Principal Engine Specifications
  29
- Abbreviations and Symbols
  30
  - Abbreviations
    30
  - Symbols
    30
- Unit Conversions
  31
- Unit Prefixes
  31
- Units of Length
  31
- Units of Volume
  31
- Units of Mass
  31
- Units of Force
  31
- Units of Torque
  31
- Units of Pressure
  31
Section 4 Periodic Maintenance

33
- Periodic Maintenance
  34
- EPA Requirements
  35
- Introduction
  35
- Safety Precautions
  35
- Periodic Maintenance Procedures
  38
  - Inspect before Starting
    38
  - After Initial 50 Hours of Operation
    40
  - Every 50 Hours of Operation
    42
  - Every 250 Hours of Operation
    47
  - Every 500 Hours of Operation
    57
  - Every 1000 Hours of Operation
    60
  - Every 2000 Hours of Operation
    61
  - Testing Engine Operation
    63
  - Long-Term Storage
    65
Section 5 Engine

67
- Introduction
  71
- Safety Precautions
  71
- Disassembling the Engine and Components
  72
- Inspecting the Cylinder Block and Components
  88
  - Inspecting Oil Passages and Freeze Plugs
    88
  - Dye Penetrant Inspection Procedure
    88
  - Replacing Freeze Plugs
    89
  - Fabricating a Freeze Plug Driver
    90
  - Measuring the Cylinder Bores
    90
  - Cylinder Head Components and Functions
    92
  - Inspecting the Cylinder Head
    94
  - Inspecting the Pistons and Piston Pins
    102
  - Inspecting the Connecting Rods
    107
  - Inspecting the Crankshaft
    110
  - Inspecting the Camshaft and Tappets
    114
  - Inspecting the Tappets
    116
  - Inspecting the Push Rods
    117
  - Inspecting the Timing Gear
    117
  - Inspecting the Idler Gear
    117
  - Indexing the Gear Timing Marks
    118
  - Inspecting the Flywheel and Housing
    119
  - Replacing the Ring Gear
    119
  - Positioning Top Dead Center
    119
  - Inspecting the Intake / Exhaust System
    120
- Assembling the Engine and Components
  121
  - Precautions before Assembling the Engine
    121
  - Installing the Tappets
    121
  - Installing the Piston Cooling Nozzles
    122
  - Installing the Camshaft Bearings
    122
  - Installing the Crankshaft
    123
  - Installing the Oil Pump
    124
  - Installing the Drive Shaft Housing
    125
  - Installing the Camshaft
    125
  - Installing the Piston Assemblies
    125
  - Installing the Oil Pan Spacer
    126
  - Installing the Oil Intake and Delivery Tubes
    126
  - Installing the Oil Pan
    127
  - Installing the Flywheel Housing Oil Seal
    127
  - Installing the Flywheel Housing
    127
  - Installing the Seawater Pump
    128
  - Installing the Idler Gear
    128
  - Installing the Oil Pressure Regulating Valve
    129
  - Installing the Coolant Passage Cover
    129
  - Installing the Fuel Injection Pump
    129
  - Installing the Flywheel
    129
  - Installing the Cylinder Head Assembly
    130
  - Installing the Intercooler
    131
  - Installing the Intake Manifold
    132
  - Installing the Marine Gear
    132
  - Installing the Push Rod and Rocker Arm Shaft Assembly
    132
  - Installing the Rocker Arm Cover
    132
  - Installing the Coolant Pump
    133
  - Installing the Drive Shaft Housing Cover
    133
  - Installing the Crankshaft V-Pulley and Damper
    133
  - Installing the Fuel Injection Nozzles
    134
  - Installing the Heat Exchanger
    136
  - Installing the Coolant Tank
    136
  - Installing the Engine Oil Cooler
    137
  - Installing the Engine Oil Filters
    137
  - Installing the Engine Coolant Hoses
    138
  - Installing the Engine Air Ducts
    140
  - Installing the Engine Turbocharger
    140
  - Installing the Mixing Elbow
    141
  - Installing the Oil Lines for the Fuel Injection Pump
    142
  - Installing the Alternator
    142
  - Installing the Starter Motor
    142
Section 6 Fuel System

143
- Fuel System
  144
- Safety Precautions
  145
- Introduction
  146
- Specifications
  147
  - Fuel System Diagram
    148
- Fuel Injection Pump / Governor / Timer
  149
- Fuel Injection Nozzle Components and Functions
  168
  - Fuel Injection Nozzle Functions
    168
- Fuel Feed Pump Components and Functions
  170
  - Fuel Feed Pump Components
    171
  - Fuel Feed Pump Specifications
    172
  - Disassembling the Fuel Feed Pump
    172
  - Inspecting the Fuel Feed Pump
    172
  - Assembling the Fuel Feed Pump
    172
  - Testing the Fuel Feed Pump
    173
- Fuel Filter Components and Functions
  175
  - Inspecting the Fuel Filter
    176
- Electronic Control System
  177
  - Engine Control System Diagram
    178
  - Sensors and Actuators
    179
  - Injection Quantity Control Diagram
    180
  - Injection Timing Control Diagram
    181
  - Timer Phase Detection
    182
  - ECU Control Data Management
    183
  - ECU Data Flow
    185
Section 7 Coolant System

187
- Coolant System
  189
- Introduction
  189
- Safety Precautions
  189
- Coolant System Components and Functions
  190
  - Coolant System Components
    191
- Seawater Pump Components and Functions
  192
  - Disassembling the Seawater Pump
    192
  - Inspecting the Seawater Pump
    193
  - Assembling the Seawater Pump
    194
- Coolant Pump Components and Functions
  195
  - Coolant System Components
    196
  - Disassembling the Coolant Pump
    197
  - Inspecting the Coolant Pump
    197
- Heat Exchanger Components and Functions
  199
  - Heat Exchanger Components
    199
  - Disassembling the Heat Exchanger
    199
  - Inspecting the Heat Exchanger
    200
  - Pressure Cap Operation
    200
  - Inspecting the Pressure Cap
    201
- Coolant Recovery Tank Components and Functions
  202
  - Installing the Coolant Recovery Tank
    202
  - Coolant Recovery Tank Precautions
    202
- Thermostat Components and Functions
  203
  - Inspecting the Thermostat
    204
  - Testing the Thermostat
    204
- Seacock Components and Functions (Optional)
  205
  - Seacock Precautions
    205
  - Inspecting the Seacock
    205
- Bilge Pump and Strainer Components and Functions (Optional)
  206
- Bilge Pump Characteristics
  207
- Bilge Pump Durability
  207
- Bilge Pump Insulation
  207
- Bilge Pump Precautions
  207
- Bilge Pump Vibration Proof
  207
- Installing the Bilge Pump
  207
- Troubleshooting the Bilge Pump
  209
Section 8 Lubrication

211
- Introduction
  213
- Safety Precautions
  213
- Lubrication Components and Functions
  214
- Oil Pump Components and Functions
  215
  - Oil Pump Specifications
    215
  - Oil Pump Components
    216
  - Removing the Oil Pump
    217
  - Inspecting the Oil Pump
    217
  - Installing the Oil Pump
    217
  - Oil Pressure Control Valve Components and Functions
    218
  - Replacing the Oil Pressure Control Valve
    218
- Oil Filter Components and Functions
  219
  - Replacing the Oil Filter
    219
- Oil Cooler Components and Functions
  220
  - Inspecting the Oil Cooler
    220
- Rotary Waste Oil Pump Components and Functions (Optional)
  220
  - Rotary Waste Oil Pump Components
    221
  - Inspecting the Waste Oil Pump
    221
Section 9 Turbocharger

223
- Introduction
  225
- Safety Precautions
  225
- Turbocharger Components and Functions
  226
  - Turbine
    227
  - Compressor
    227
  - Bearings
    227
  - Seal Structure of the Compressor Housing
    227
- Maintenance Standards
  228
  - Standard Limits
    228
  - Torque Chart
    230
- Turbocharger Periodic Inspections
  231
  - Inspection Intervals
    231
  - Checking the Rotor Rotation
    231
  - Checking the Rotor Axial Play
    232
  - Checking the Rotor Radial Play
    233
- Disassembling the Turbocharger
  234
- Inspecting the Turbocharger
  237
  - Inspecting Major Items
    237
  - Cleaning the Turbocharger
    237
  - Inspecting the Turbocharger Components
    238
- Assembling the Turbocharger
  241
  - Installing the Floating Bearings
    241
  - Installing the Turbine Rotor Shaft
    242
  - Installing the Thrust Bearing
    242
  - Installing the Seal Plate
    242
  - Installing the Compressor Impeller
    243
  - Installing the Turbine Housing
    243
  - Installing the Compressor Housing
    243
  - Connecting the Boost Hose
    243
  - Post-Assembly Inspection
    243
- Handling the Turbocharger
  244
  - Precautions for Installing the Turbocharger to the Engine
    244
- Troubleshooting the Turbocharger
  245
  - Black Smoke
    245
  - White Smoke
    246
  - Excessive Oil Consumption
    246
  - Reduced Engine Power
    246
  - Poor Follow-Up of the Turbocharger
    246
  - Unusual Sound or Vibration
    247
Section 10 Starter

249
- Introduction
  251
- Safety Precautions
  251
- Starter Components and Functions
  252
  - Starter Specifications
    252
  - Starter Characteristics
    253
  - Starter Components
    254
  - Starter Operation
    256
  - Starter Wiring Diagram
    256
Section 11 Alternator

257
- Safety Precautions
  259
- Introduction
  260
- Alternator Components and Functions (12V / 80A)
  261
  - Alternator Specifications
    261
  - Alternator Components
    261
  - Alternator Wiring Diagram
    264
  - Alternator Characteristics
    265
  - Inspecting the Alternator
    265
Section 12 Electrical and Ecu

267
- Battery Components and Functions
  269
  - Battery Capacity and Battery Cables
    269
  - Inspecting the Battery
    270
  - Charging the Battery
    271
  - Precautions for Battery Storage
    273
- Safety Precautions
  269
- Wiring Diagram
  274
  - ECU Connector Pin Configuration
    275
  - Warning Devices
    276
  - Sensor Locations
    276
  - Sensors for Oil Pressure and Boost Pressure
    278
  - Sensors for Water, Oil and Fuel Temperatures
    278
- Air Heater Components and Functions
  279
  - Air Heater Operation
    279
- Fuse, Relay and Harness Components
  282
  - Fuse Chart
    282
  - Digital Display
    287
  - Rocker Switch Panel
    289
  - Control Head (Shift and Throttle)
    290
Section 13 Troubleshooting

291
- Troubleshooting
  292
- Introduction
  293
- Safety Precautions
  293
- Preparation before Troubleshooting
  294
  - Teleflex Display Indications
    294
- Troubleshooting by Symptom
  295
- Troubleshooting Fuses, Relays and Harnesses
  311
  - Fuse, Relay and Harness
    311
  - Fuse Burns out
    311
  - Test Check
    311
  - Checking a Fuse
    311
  - Troubleshooting Blown Fuses
    312
- Electronic Control System
  316
  - Engine Control System Diagram
    316
  - Terms
    318
- Troubleshooting by Dtc Fault Codes
  318
  - List of DTC (Diagnostic Trouble Codes)
    320
  - TFX Diagnostic Screen Display Procedure 3
    320
  - Troubleshooting the Temperature Sensor
    330
  - Troubleshooting the Pressure Sensor
    344
  - Wiring Diagrams
    371
  - Service Standards
    381
    
    Engine
    381
    
    Cylinder Head
    382
    
    Valve Spring
    382
    
    Camshaft and Gear Train
    383
    
    Idler Gear Shaft and Bushing
    383
    
    Cylinder Block
    384
    
    Piston and Ring
    385
    
    Connecting Rod
    387
  - Tightening Torque for Bolts and Nuts
    388
    
    Main Bolt and Nut
    388
    
    Standard Bolts and Nuts (Without Oil)
    389

Yanmar 6LY3 series Operation Manual (136 pages)

MARINE

Brand: Yanmar | Category: Engine | Size: 16.85 MB

Introduction

3
- Record of Ownership
  4
- Table of Contents
  5
Table of Contents

9
Safety

9
- Safety Precautions
  10
  - Before You Operate
    10
  - During Operation and Maintenance
    11
Product Overview

29
- Yanmar 6LY3 Features and Applications
  29
  - Component Identification
    30
    
    Operation Side
    30
    
    Non-Operation Side
    31
  - Location of Labels
    32
- Nameplate
  33
  - Function of Major Components
    34
  - Electronic Control System (ECS)
    35
    
    Display
    36
Before You Operate

43
- Fire and Explosion
  44
- Diesel Fuel
  48
  - Diesel Fuel Specifications
    48
  - Filling the Fuel Tank
    49
  - Bleeding the Fuel System
    51
- Engine Oil
  52
  - Engine Oil Specifications
    52
  - Engine Oil Viscosity
    53
  - Checking Engine Oil
    53
  - Selection of Marine Gear Oil
    53
- Engine Coolant
  54
  - Engine Coolant Specifications
    55
  - Coolant (Fresh Water Cooling System)
    55
- Cranking
  58
- Daily Checks
  59
Engine Operation

61
- Engine Operation
  62
- Starting the Engine
  72
  - Before Starting the Engine
    72
  - To Start the Engine
    72
  - Shifting
    74
- Cautions During Operation
  75
- Shutting down the Engine
  78
  - Normal Shutdown
    78
  - Emergency Shutdown
    78
Periodic Maintenance

81
- Safety Precautions
  81
  - Before You Operate
    81
  - During Operation and Maintenance
    82
- Precautions
  98
  - The Importance of Periodic Maintenance
    98
  - Performing Periodic Maintenance
    99
  - The Importance of Daily Checks
    99
  - Keep a Log of Engine Hours and Daily Checks
    99
  - Yanmar Replacement Parts
    99
  - Tools Required
    99
  - Ask Your Authorized Yanmar Marine Dealer for Help
    99
  - Required EPA Maintenance - USA Only
    100
  - EPA Installation Requirements - USA Only
    100
  - Tightening Fasteners
    100
  - Standard Torque Chart
    100
  - Periodic Maintenance Schedule
    101
    
    Inspection and Maintenance of EPA Emission-Related Parts
    103
  - Periodic Maintenance Procedures
    104
    
    After Initial 50 Hours of Operation
    104
    
    Oil Filter
    104
    
    Replace Engine Oil and Engine
    104
    
    Adjust the Propeller Shaft Alignment
    106
    
    Check the Electronic Control System Operation
    106
    
    Drain Fuel Filter and Fuel Filter / Water Separator
    107
    
    Every 50 Hours of Operation
    107
    
    Check the Battery
    109
    
    Adjust Alternator V-Belt Tension
    111
    
    Adjust Intake / Exhaust Valve Clearance (1St Time)
    112
    
    Check the Fuel Injector Spray Pattern
    112
    
    Every 250 Hours of Operation
    112
    
    Drain the Fuel Tank
    113
    
    Check the Seawater Pump Impeller
    114
    
    Replace the Engine Oil (Crankcase)
    114
    
    Replace the Engine Oil Filter Element
    114
    
    Replace the Fuel Filter Element
    114
    
    Clean the Air Intake Silencer
    115
    
    Replace the Anode
    115
    
    Check / Replace the Flexible Engine Mounts
    116
    
    Check the Wiring Connectors
    116
    
    Clean the Exhaust / Water Mixing Elbow
    116
    
    Clean the Turbocharger Blower
    116
    
    Flush the Aftercooler
    116
    
    Tighten All Major Nuts and Bolts
    116
    
    Adjust the Propeller Shaft Alignment
    117
    
    Check Alternator Belt Tension
    117
    
    Every 500 Hours of Operation
    117
    
    Replace Engine Coolant
    117
    
    Replace the Seawater Pump Impeller
    117
    
    Adjust Intake / Exhaust Valve Clearance
    118
    
    Check the Fuel Injector Spray Pattern
    118
    
    Clean and Check the Seawater Passages
    118
    
    Every 1000 Hours of Operation
    118
    
    Replace Alternator Belt
    118
    
    Replace Flexible Engine Mounts
    118
    
    Clean Engine Oil Cooler
    119
    
    Clean Seawater and Engine Coolant System
    119
    
    Every 2000 Hours of Operation
    119
    
    Overhaul and Check Fuel Feed Pump
    119
    
    Replace Rubber Fuel Hoses
    119
  - EPA Requirements
    120
  - EPA Certification Plates
    120
  - Conditions to Ensure Compliance with EPA Emission Standards
    120
  - Inspection and Maintenance
    121
Troubleshooting

123
- Troubleshooting Chart
  124
- Troubleshooting Information
  125
Long-Term Storage

127
- Before You Place the Engine in Long-Term Storage
  127
- Returning the Engine to Service
  128
Specifications

129
- Principal Engine Specifications
  129
- Epa Warranty Usa Only
  131

Yanmar 6LY3 series Technical Manual (87 pages)

Electronic Control System

Brand: Yanmar | Category: Engine | Size: 4.8 MB

Table of Contents
3
Components
7
System Overview
9
I5601E Digital Display
9
Specifi Cations
11
Main Menu
13
Control Head
25
Gauges
35
Specifi Cations
36
Specifi Cations
39
System Default Settings
45
NMEA 2000® Network
45
System Diagrams
50
Power Diagram Outline
53
Transmission Diagrams
59
Twin Disc
59
Cable Information
63
Key Switch Panel
67
Deutsch Connectors
69
Mounting Templates
72
St Station Ignition Panel - CP19100
74
St Station Key Swtich Panel - CE40100
76
Troubleshooting
79
Parts Information
81

Yanmar 6LY3 series Operation Manual (24 pages)

Electronic Control System

Brand: Yanmar | Category: Engine | Size: 6.33 MB

Table of Contents
3
System Overview
4
Helm Components
4
Start up
5
Redundant (Back Up) Throttle
5
Shift & Throttle Control Head Functions
8
Control Head Operation
8
Operation
9
Detailed Operation of the Control Head
9
Control Head Button Functions
9
Control Station Selection
10
Indicator Dimming Feature
10
Shift Disconnect
11
Cruise Synchronization
12
Power Train Synchronization
12
Split Range Throttle
13
Trolling Mode (Option)
14
I5601E Digital Display Alarms/Diagnostic Code Screens
15
Engine Alarms
16
Engine Diagnostic Codes
16
Maintenance Warning
16
Diagnostics
17
Power Reduction Mode
17
Appendix A: I5601E Digital Display Setup
18
Unlocking" the Hot Keys
19
User Settings and Factory Settings
20
Quad Screen Parameters
21
Appendix B: I5601E Menu Navigation
22
Appendix C: Default Settings
23
Appendix D: Fuses
24
Appendix E: Trouble Codes
24

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Yanmar 6LY3 series Manuals

Yanmar 6LY3 series Service Manual (390 pages)

Table of Contents

Section 3 General Service Information

Section 4 Periodic Maintenance

Section 5 Engine

Section 6 Fuel System

Section 7 Coolant System

Section 8 Lubrication

Section 9 Turbocharger

Section 10 Starter

Section 11 Alternator

Section 12 Electrical and Ecu

Section 13 Troubleshooting

Yanmar 6LY3 series Operation Manual (136 pages)

Table of Contents

Introduction

Table of Contents

Safety

Product Overview

Before You Operate

Engine Operation

Periodic Maintenance

Troubleshooting

Long-Term Storage

Specifications

Yanmar 6LY3 series Technical Manual (87 pages)

Table of Contents

Yanmar 6LY3 series Operation Manual (24 pages)

Table of Contents

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