Yanmar 6LY3 series User manual

6LY3
series
OPERATION MANUAL
6LY3 Operation Manual
P/N: 0A1957-G0000
MARINE
ENGINES
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ii 6LY3 Operation Manual
Disclaimers:
We reserve the right to change specifications and to improve our products without notice
or obligation. Yanmar and are registered trademarks of Yanmar Co., Ltd. in
Japan, the United States and / or other countries.
All Rights Reserved:
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.
© 2005 Yanmar Marine International.
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6LY3 Operation Manual iii
INTRODUCTION
6LY3 Operation Manual
Welcome to the world of Yanmar Marine!
Yanmar Marine offers engines, drive
systems and accessories for all types of
boats, from runabouts to sailboats, and
from cruisers to mega yachts. In marine
leisure boating, the worldwide reputation of
Yanmar Marine is second to none. We
design our engines to respect nature. This
means quieter engines, with minimal
vibrations, cleaner than ever. All of our
engines designed after 1996 meet most of
the present and future emission
regulations, like BSO II, SAV, EPA II, IMO
and RCD.
To help you enjoy your Yanmar 6LY3
engine for many years to come, please
follow these recommendations:
• Read and understand this Operation
Manual before you operate the machine
to ensure that you follow safe operating
practices and maintenance procedures.
• Keep this Operation Manual in a
convenient place for easy access.
• If this Operation Manual is lost or
damaged, order a new one from your
authorized Yanmar marine dealer or
distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should
be considered a permanent part of the
engine and remain with it.
• Constant efforts are made to improve the
quality and performance of Yanmar
products, so some details included in
this Operation Manual may differ slightly
from your engine. If you have any
questions about these differences,
please contact your authorized Yanmar
marine dealer or distributor.
• The specifications and components
(instrument panel, fuel tank, etc.)
described in this manual may differ from
ones installed on your vessel. Please
refer to the manual provided by the
manufacturer of these components.
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INTRODUCTION
iv 6LY3 Operation Manual
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:___________________________________________________________
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6LY3 Operation Manual 1
TABLE OF
CONTENTS
6LY3 Operation Manual
Page
Introduction..................................................................... iii
Record of Ownership........................................... iv
Table of Contents ........................................................... 1
Safety............................................................................... 1
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................................................................ 25
Function of Major Components ......................... 26
Electronic Control System (ECS)....................... 27
Display ........................................................ 28
Before You Operate...................................................... 35
Diesel Fuel ............................................................... 40
Diesel Fuel Specifications ................................. 40
Filling the Fuel Tank .......................................... 41
Bleeding the Fuel System.................................. 43
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TABLE OF CONTENTS
26LY3 Operation Manual
Engine Oil ................................................................. 44
Engine Oil Specifications ................................... 44
Engine Oil Viscosity ........................................... 45
Checking Engine Oil........................................... 45
Selection of Marine Gear Oil .............................. 45
Engine Coolant ......................................................... 46
Engine Coolant Specifications ........................... 47
Coolant (Fresh Water Cooling System) ............. 47
Cranking ................................................................... 50
Daily Checks............................................................. 51
Visual Checks .................................................... 51
Check Diesel Fuel, Engine Oil,
and Engine Coolant Levels.......................... 52
Checking and Refilling Marine Gear Oil ............. 52
Checking the Control Head ................................ 52
Checking the Alarm Indicators ........................... 52
Preparing Fuel, Oil, and Coolant in Reserve...... 52
Engine Operation .......................................................... 53
Starting the Engine ................................................... 64
Before Starting the Engine ................................. 64
To Start the Engine ............................................ 64
Shifting ............................................................... 66
Cautions During Operation ....................................... 67
Shutting Down the Engine ........................................ 70
Normal Shutdown............................................... 70
Emergency Shutdown ........................................ 70
Periodic Maintenance ................................................... 73
Safety Precautions ................................................... 73
Before You Operate ........................................... 73
During Operation and Maintenance ................... 74
Precautions............................................................... 90
The Importance of Periodic Maintenance .......... 90
Performing Periodic Maintenance ...................... 91
The Importance of Daily Checks ........................ 91
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 ......................................... 92
Standard Torque Chart ...................................... 92
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TABLE OF CONTENTS
6LY3 Operation Manual 3
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 ................................. 98
Adjust the Propeller Shaft Alignment .... 98
Every 50 Hours of Operation....................... 99
Drain Fuel Filter and Fuel Filter / Water
Separator .............................................. 99
Check the Battery ............................... 101
Adjust Alternator V-Belt Tension......... 103
Every 250 Hours of Operation................... 104
Check the Fuel Injector Spray Pattern 104
Adjust Intake / Exhaust Valve
Clearance (1st Time) .......................... 104
Drain the Fuel Tank ............................ 105
Replace the Fuel Filter Element ......... 106
Replace the Engine Oil (Crankcase) .. 106
Replace the Engine Oil Filter
Element............................................... 106
Check the Seawater Pump Impeller ... 106
Replace the Anode ............................. 107
Clean the Air Intake Silencer .............. 107
Clean the Exhaust / Water Mixing
Elbow .................................................. 108
Clean the Turbocharger Blower.......... 108
Flush the Aftercooler........................... 108
Check the Wiring Connectors ............. 108
Tighten All Major Nuts and Bolts ........ 108
Check / Replace the Flexible Engine
Mounts ................................................ 108
Replace Engine Coolant ..................... 109
Every 500 Hours of Operation................... 109
Replace the Seawater Pump Impeller 109
Adjust the Propeller Shaft Alignment .. 109
Check Alternator Belt Tension ............ 109
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TABLE OF CONTENTS
46LY3 Operation Manual
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 ................. 111
Overhaul and Check Fuel Feed
Pump................................................... 111
Clean Engine Oil Cooler...................... 111
Clean Seawater and Engine
Coolant System................................... 111
Replace Rubber Fuel Hoses ............... 111
EPA Requirements........................................... 112
EPA Certification Plates ................................... 112
Conditions to Ensure Compliance with EPA
Emission Standards ......................................... 112
Inspection and Maintenance ............................ 113
Troubleshooting.......................................................... 115
Troubleshooting Chart...................................... 116
Troubleshooting Information ............................ 117
Long-Term Storage..................................................... 119
Before You Place the Engine in Long-Term
Storage ................................................................... 119
Returning the Engine to Service............................. 120
Specifications.............................................................. 121
Principal Engine Specifications ........................ 121
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6LY3 Operation Manual 1
SAFETY
6LY3 Operation Manual
Yanmar considers safety of great
importance and recommends that anyone
who comes into close contact with its
products, such as those who install,
operate, maintain or service Yanmar
products, exercise care, common sense
and comply with the safety information in
this manual and on the machine’s safety
labels. Keep the labels from becoming
dirty or torn and replace them if they are
lost or damaged. Also, if you need to
replace a part that has a label attached to
it, make sure you order the new part and
label at the same time.
A
m
This safety alert symbol
appears with most safety
statements. It means
attention, become alert, your
safety is involved! Please
read and abide by the
message that follows the
safety alert symbol.
ADANGER
Danger (the word “DANGER” is
in white letters with a red
rectangle behind it) – indicates
an imminently hazardous
situation which, if not avoided,
will result in death or serious
injury. Danger is limited to the
most extreme situations.
0000001en
AWARNING
Warning (the word “WARNING”
is in black letters with an orange
rectangle behind it) – indicates a
potentially hazardous situation
which, if not avoided, could
result in death or serious injury.
0000001en
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SAFETY
26LY3 Operation Manual
SAFETY PRECAUTIONS
Before You Operate
ACAUTION
Caution (the word “CAUTION” is
in black letters with a yellow
rectangle behind it) – indicates a
potentially hazardous situation
which, if not avoided, may result
in minor or moderate injury.
0000001en
CAUTION
Caution without the safety alert
symbol indicates a potentially
hazardous situation that can
cause damage to the engine,
personal property and / or the
environment or cause the engine
to operate improperly.
0000001enMarine
CAUTION
NEVER permit anyone to install
or operate the engine without
proper training.
• Read and understand this
Operation Manual before you
operate or service the engine
to ensure that you follow safe
operating practices and
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
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SAFETY
6LY3 Operation Manual 3
During Operation and
Maintenance
ADANGER
EXPLOSION HAZARD!
• Keep the area around the
battery well-ventilated. While
the engine is running or the
battery is charging, hydrogen
gas is produced which can be
easily ignited.
• Keep sparks, open flame and
any other form of ignition away
while the engine is running or
battery is charging.
• Failure to comply will result in
death or serious injury.
0000003en
ADANGER
SCALD HAZARD!
• NEVER remove the fill cap if
the engine is hot. Steam and
hot engine coolant will spurt
out and seriously burn you.
Allow the engine to cool down
before you attempt to remove
the fill cap.
• Securely tighten the fill cap
after you check the heat
exchanger. Steam can spurt
out during engine operation if
the cap is loose.
• ALWAYS check the level of
engine coolant by observing
the reserve tank.
• Failure to comply will result in
death or serious injury.
0000002en6LY3
ADANGER
FIRE AND EXPLOSION
HAZARD!
• Diesel fuel is flammable and
explosive under certain
conditions.
• NEVER use diesel fuel as a
cleaning agent.
• Failure to comply will result in
death or serious injury.
0000012en
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SAFETY
46LY3 Operation Manual
ADANGER
FIRE AND EXPLOSION
HAZARD!
• Diesel fuel is flammable and
explosive under certain
conditions.
• NEVER remove the fuel cap
with the engine running.
• Failure to comply will result in
death or serious injury.
0000011en
ADANGER
FIRE AND EXPLOSION
HAZARD!
• Only use the key switch to start
the engine.
• NEVER jump start the engine.
Sparks caused by shorting the
battery to the starter terminals
may cause a fire or explosion.
• Failure to comply will result in
death or serious injury.
0000004en
ADANGER
FIRE AND EXPLOSION
HAZARD!
• Diesel fuel is flammable and
explosive under certain
conditions.
• Only fill the fuel tank with
diesel fuel. Filling the fuel tank
with gasoline may result in a
fire and will damage the
engine.
• NEVER refuel with the engine
running.
• Wipe up all spills immediately.
• Keep sparks, open flames or
any other form of ignition
(match, cigarette, static
electric source) well away
when refueling.
• NEVER overfill the fuel tank.
• Fill the fuel tank. Store any
containers containing fuel in a
well-ventilated area, away from
any combustibles or sources
of ignition.
• Failure to comply will result in
death or serious injury.
0000005en
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SAFETY
6LY3 Operation Manual 5
ADANGER
EXPLOSION HAZARD!
• NEVER check the remaining
battery charge by shorting out
the terminals. This will result in
a spark and may cause an
explosion or fire. Use a
hydrometer to check the
remaining battery charge.
• If the electrolyte is frozen,
slowly warm the battery before
you recharge it.
• Failure to comply will result in
death or serious injury.
0000007en
ADANGER
FIRE AND EXPLOSION
HAZARD!
• Diesel fuel is extremely
flammable and explosive under
certain conditions.
• Before you operate the engine,
check for fuel leaks. Replace
rubberized fuel hoses every
two years or every 2000 hours
of engine operation, whichever
comes first, even if the engine
has been out of service.
Rubberized fuel lines tend to
dry out and become brittle
after two years or 2000 hours
of engine operation, whichever
comes first.
• Failure to comply will result in
death or serious injury.
0000015en
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SAFETY
66LY3 Operation Manual
ADANGER
FIRE AND EXPLOSION
HAZARD!
• Diesel fuel is extremely
flammable and explosive under
certain conditions.
• When you prime the fuel
system, operate the fuel
priming lever of the
mechanical fuel pump several
times until the fuel filter cup is
filled with fuel.
• NEVER open the air vent valve
while the fuel system is being
primed. The fuel filter has an
internal air bleed port.
• Failure to comply will result in
death or serious injury.
0000016en
ADANGER
CRUSH HAZARD!
• When you need to transport an
engine for repair have a helper
assist you attach it to a hoist
and load it on a truck.
• NEVER stand under hoisted
engine. If the hoist mechanism
fails, the engine will fall on
you, causing serious injury or
death.
• Failure to comply will result in
death or serious injury.
0000008en
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SAFETY
6LY3 Operation Manual 7
AWARNING
SEVER HAZARD!
• Keep hands and other body
parts away from
moving / rotating parts such as
the flywheel or PTO shaft.
• Wear tight fitting clothing and
keep your hair short or tie it
back while the engine is
running.
• Remove all jewelry before you
operate or service the engine.
• NEVER start the engine in
gear. Sudden movement of the
engine and / or vessel could
cause death or serious
personal injury.
• NEVER operate the engine
without the guards in place.
• Before you start the engine
make sure that all bystanders
are clear of the area.
• Keep children and pets away
while the engine is operating.
• Check before starting the
engine that any tools or shop
rags used during maintenance
have been removed from the
area.
• Failure to comply could result
in death or serious injury.
0000002enMarine
AWARNING
EXHAUST HAZARD!
• NEVER operate the engine in
an enclosed area such as a
garage, tunnel, underground
room, manhole or ship’s hold
without proper ventilation.
• NEVER block windows, vents,
or other means of ventilation if
the engine is operating in an
enclosed area. All internal
combustion engines create
carbon monoxide gas during
operation. Accumulation of
this gas within an enclosure
could cause illness or even
death.
• Make sure that all connections
are tightened to specifications
after repair is made to the
exhaust system.
• Failure to comply could result
in death or serious injury.
0000003en
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SAFETY
86LY3 Operation Manual
AWARNING
ALCOHOL AND DRUG
HAZARD!
• NEVER operate the engine
while you are under the
influence of alcohol or drugs.
• NEVER operate the engine
when you are feeling ill.
• Failure to comply could result
in death or serious injury.
0000004en
AWARNING
EXPOSURE HAZARD!
• Wear personal protective
equipment such as gloves,
work shoes, eye and hearing
protection as required by the
task at hand.
• NEVER wear jewelry,
unbuttoned cuffs, ties or loose
fitting clothing when you are
working near moving / rotating
parts such as the flywheel or
PTO shaft.
• ALWAYS tie back long hair
when you are working near
moving / rotating parts such as
a flywheel or PTO shaft.
• NEVER operate the engine
while wearing a headset to
listen to music or radio
because it will be difficult to
hear the warning signals.
• Failure to comply could result
in death or serious injury.
0000005enMarine
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SAFETY
6LY3 Operation Manual 9
AWARNING
SUDDEN MOVEMENT
HAZARD!
• Be sure the boat is in open
water away from other boats,
docks, and other obstructions
before increasing rpm.
• Failure to comply could result
in death or serious injury.
0000006enMarine
AWARNING
BURN HAZARD!
• Batteries contain sulfuric acid.
NEVER allow battery fluid to
come in contact with clothing,
skin or eyes. Severe burns
could result. ALWAYS wear
safety goggles and protective
clothing when servicing the
battery. If battery fluid contacts
the eyes and / or skin,
immediately flush the affected
area with a large amount of
clean water and obtain prompt
medical treatment.
• Failure to comply could result
in death or serious injury.
0000007en
AWARNING
HIGH PRESSURE
HAZARD!
• Avoid skin contact with high
pressure diesel fuel spray
caused by a fuel system leak
such as a broken fuel injection
line. High pressure fuel can
penetrate your skin and result
in serious injury. If you are
exposed to high pressure fuel
spray, obtain prompt medical
treatment.
• NEVER 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 the damage.
• Failure to comply could result
in death or serious injury.
0000008enMarine
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SAFETY
10 6LY3 Operation Manual
AWARNING
SHOCK HAZARD!
• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.
• Check the electrical harnesses
for cracks, abrasions, and
damaged or corroded
connectors. ALWAYS keep the
connectors and terminals
clean.
• Failure to comply could result
in death or serious injury.
0000009en
AWARNING
ENTANGLEMENT
HAZARD!
• Stop the engine before you
begin to service it.
• NEVER leave the key in the key
switch when you are servicing
the engine. Someone may
accidentally start the engine
and not realize you are
servicing it. This could result
in a serious injury.
• If you must service the engine
while it is operating, remove all
jewelry, tie back long hair, and
keep your hands, other body
parts and clothing away from
moving / rotating parts.
• Failure to comply could result
in death or serious injury.
0000010en
AWARNING
BURN HAZARD!
• Wait until the engine cools
before you drain the engine
coolant. Hot engine coolant
may splash and burn you.
• Failure to comply could result
in death or serious injury.
0000016en
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SAFETY
6LY3 Operation Manual 11
AWARNING
BURN HAZARD!
• If you must drain the engine oil
while it is still hot, stay clear of
the hot engine oil to avoid
being burned.
• ALWAYS wear eye protection.
• Failure to comply could result
in death or serious injury.
0000011en
AWARNING
BURN HAZARD!
• Keep your hands, and other
body parts, away from hot
engine surfaces such as the
muffler, exhaust pipe,
turbocharger (if equipped) and
engine block during operation
and shortly after you shut the
engine down. These surfaces
are extremely hot while the
engine is operating and could
seriously burn you.
• Failure to comply could result
in death or serious injury.
0000015en
AWARNING
FIRE HAZARD!
• Undersized wiring systems can
cause an electrical fire.
• Failure to comply could result
in death or serious injury.
0000027en
ACAUTION
COOLANT HAZARD!
• Wear eye protection and
rubber gloves when you
handle Long Life or Extended
Life engine coolant. If contact
with the eyes or skin should
occur, flush eyes and wash
immediately with clean water.
• Failure to comply may result in
minor or moderate injury.
0000005en
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SAFETY
12 6LY3 Operation Manual
ACAUTION
FLYING OBJECT HAZARD!
• ALWAYS wear eye protection
when servicing engine and
when using compressed air or
high-pressure water. Dust,
flying debris, compressed air,
pressurized water or steam
may injure your eyes.
• Failure to comply may result in
minor or moderate injury.
0000003en
CAUTION
• Only use diesel fuels
recommended by Yanmar for
the best engine performance,
to prevent engine damage and
to comply with EPA warranty
requirements.
• Only use clean diesel fuel.
• NEVER remove primary
strainer from the fuel tank filler
port. If removed, dirt and
debris could get into the fuel
system causing it to clog.
0000004enMarine
CAUTION
If any problem is noted during
the visual check, the necessary
corrective action should be
taken before you operate the
engine.
0000021en
CAUTION
Be sure to close the seacock.
Neglecting to close the seacock
could allow water to leak into the
boat and may cause it to sink.
0000152en
CAUTION
The illustrations and
descriptions of optional
equipment in this manual, such
as the operator’s console, are for
a typical engine installation.
Refer to the documentation
supplied by the optional
equipment manufacturer for
specific operation and
maintenance instructions.
0000018en
CAUTION
If any indicator illuminates
during engine operation, stop
the engine immediately.
Determine the cause and repair
the problem before you continue
to operate the engine.
0000029en
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