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TROUBLESHOOTING

Troubleshooting by DTC Fault Codes

13-50

6LY3 Service Manual

P0219/0 (Engine Over Rev.)

DTC Fault Code

Fault

Troubleshooting Procedure

1. Check if there is / are any other DTC detected

such as RACK POSITION SENSOR or RACK

ACTUATOR related DTC.
If there is / are, repair the DTC first.

2. Check if the DTC is detected by actual

over-revolution faults.
If it was not over the revolution check the speed

sensor. (Look for contaminants on the sensor

core, connector, wire harness, etc.)

3. Check the fuel injection pump.
4. Check the injection nozzle and fuel line.
5. Check the fuel injection pump lag (rack actuator

performance).
If lag results in fault, replace the fuel injection

pump (including position sensor amplifier).

DTC

P0219/0

Engine Over Revolutions

DTC / FMI

1. Condition, 2. Fault, 3. Time to Detect, 4. Display

Check Point

P0219/0

1. Engine running
2. Engine speed of the cam or crank exceeds 3900 rpm.
3. —
4. OVER REV on the TELEFLEX display

Injector

FIP

Crank / cam speed sensor

Pulsar (gear)

Wire harness

Fail Mode

Rack needs to be set at stop position.

Break rack actuator relay

Limited Operation

Engine stop

Fail Release

Remarks

Require key off to reset fail mode

DTC / FMI

Probable Cause

P0219/0

1. Speed sensor (crank or cam)

• wire harness
• contaminants on the sensor core

2. Rack position sensor
3. Rack actuator performance
4. Fuel injection pump
5. Injector
6. Fuel system

Summary of Contents for 6LY3 series

Page 1: ...6LY3 series 6LY3 Service Manual SERVICE MANUAL P N 0BLY3 U00100 MARINE ENGINES ...

Page 2: ... on the latest information available at the time of publishing The illustrations used in this manual are intended as representative reference views only Moreover because of our continuous product improvement policy we may modify information illustrations and or specifications to explain and or exemplify a product service or maintenance improvement We reserve the right to make any change at any tim...

Page 3: ...TENTS Page Introduction 1 1 Safety 2 1 General Service Information 3 1 Periodic Maintenance 4 1 Engine 5 1 Fuel System 6 1 Coolant System 7 1 Lubrication 8 1 Turbocharger 9 1 Starter 10 1 Alternator 11 1 Electrical and ECU 12 1 Troubleshooting 13 1 Service Standards 14 1 ...

Page 4: ...TABLE OF CONTENTS iv 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 5: ...ervice Manual completely before starting with repairs Along with standard tools Yanmar recommends the use of special tools necessary to perform repairs correctly Yanmar products are continuously undergoing improvement This Service Manual has been checked carefully in order to avoid errors However Yanmar is not liable for any misrepresentations errors of description or omissions Contact your author...

Page 6: ...rmation If a page or number of pages should be replaced the replacement information is sent along with a revised Revision Control Table Discard the older obsolete information At times the revision involves inserting additional pages in one or more sections Replace the Revision Control Table and insert the new pages This method of revision control represents the most cost effective solution to prov...

Page 7: ...d replace them if they are lost or damaged Also if a part needs to be replaced that has a decal attached to it make sure to order the new part and decal at the same time Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not ...

Page 8: ...re additional reminders for safe operating and maintenance techniques See your authorized Yanmar marine dealer or distributor for additional training Crush Hazard NEVER stand under a hoisted engine If the hoist mechanism fails the engine will fall on you ALWAYS secure the engine solidly to prevent the engine from falling during maintenance The safety messages that follow have WARNING level hazards...

Page 9: ...y tie back long hair and keep hands other body parts and clothing away from moving rotating parts Piercing 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 f...

Page 10: ... the component to be welded and as close as possible to the welding point NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket When welding is complete reconnect the leads to the alternator and engine control unit prior to reconnecting the batteries ALWAYS keep the electrical connectors and terminals clean Check the electrical harne...

Page 11: ... ALWAYS wear personal protective equipment including appropriate clothing gloves work shoes eye and hearing protection as required by the task at hand Tool Hazard ALWAYS remove any tools or shop rags used during maintenance from the area before operation The safety messages that follow have CAUTION level hazards These safety messages describe a hazardous situation which if not avoided could result...

Page 12: ... dealer or distributor Modifications may impair the engine s safety and performance characteristics and shorten the engine s life Any alterations to this engine may void its warranty Be sure to use Yanmar genuine replacement parts 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 Consult ...

Page 13: ...s marine engines Figure 2 1 Figure 2 1 1 Part Number 128296 07300 2 Part Number 120324 07240 3 Part Number 119773 07280 4 Part Number 128296 07260 5 Part Number 128296 07350 6 Part Number 119578 07890 E 003025 02E DO NOT STEP ON COVERS POSSIBILITY OF A FALL 1 2 3 4 5 6 0006329 DO NOT STEP ON COVERS POSSIBILITY OF A FALL LOW FULL NEVER pour the engine oil across the full line 119773 07280 ...

Page 14: ...SAFETY Location of Safety Decals 2 8 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 15: ...gine Oil Specifications 3 8 Marine Gear Oil 3 8 Engine Coolant 3 9 Handling of Coolant 3 9 Engine Outline Drawings 3 10 6LY3 ETP STP UTP YT 15 MOUNT 3 10 6LY3 ETP 3 11 Exhaust Gas Emission Regulations 3 12 Engine Identification 3 12 EPA Exhaust Gas Emission Standard 3 13 EPA Guarantee Conditions for Emission Standard 3 13 Engine Nameplate 3 14 Reduction and Reversing Gear 3 14 Principal Engine Spe...

Page 16: ...nual 2007 Yanmar Marine International Unit Conversions 3 17 Unit Prefixes 3 17 Units of Length 3 17 Units of Volume 3 17 Units of Mass 3 17 Units of Force 3 17 Units of Torque 3 17 Units of Pressure 3 17 Units of Power 3 17 Units of Temperature 3 17 ...

Page 17: ...GENERAL SERVICE INFORMATION Safety Precautions 12 05 6LY3 Service Manual 3 3 2007 Yanmar Marine International SAFETY PRECAUTIONS Before servicing the engine review the Safety Section on page 2 1 ...

Page 18: ...ETP Exterior Views 3 4 6LY3 Service Manual 2007 Yanmar Marine International 6LY3 ETP EXTERIOR VIEWS Operation Side Figure 3 1 Figure 3 1 Non Operation Side Figure 3 2 Figure 3 2 0006254 3 4 5 6 7 8 9 1 2 0006255 11 10 17 16 15 14 13 12 ...

Page 19: ...ne International 1 Filler Cap 2 Electrical Control Unit Cover 3 Fuel Injection Pump 4 Oil Cooler 5 Oil Filter 6 Intercooler 7 Flywheel 8 Air Silencer 9 Turbocharger 10 Coolant Tank Exhaust Manifold 11 Dipstick 12 Heat Exchanger 13 Seawater Pump 14 Alternator 15 V Belt 16 Fuel Filter 17 Coolant Pump ...

Page 20: ...nal Fuel Requirements Fuel cetane number should equal 45 or higher Sulfur content should not exceed 0 5 by volume Preferably it should be below 0 05 Water and sediment in the diesel fuel should not exceed 0 05 by volume Ash should not exceed 0 01 by mass Carbon residue content of the diesel fuel should not exceed 0 35 by volume Preferably it should be below 0 1 Total aromatic content of the diesel...

Page 21: ...he clear filtered fuel from the upper middle section of the container only Figure 3 3 leaving any contaminated fuel at the bottom Figure 3 3 Figure 3 3 Diesel Fuel Lines Install the fuel supply line between the fuel tank and the fuel injection pump Install a drain cock at the bottom of the fuel tank to remove water and dust Install a fuel water separator and a fuel filter in the middle of the fuel...

Page 22: ... 4 ACEA E 1 E 2 B JASO DH 2 DL 1 Additional Technical Engine Oil Requirements The engine oil must be changed when the Total Base Number TBN has been reduced to 2 0 TBN mgKOH g test method JIS K 2501 5 2 2 HCI ASTM D4739 HCI Handling Engine Oil 1 Check that the engine oil oil storage container and filling equipment are free of sediment and water 2 NEVER mix engine oils of different types 3 Extract ...

Page 23: ...s be sure to add LLC to soft water It is particularly important to add LLC during cold weather Without LLC coolant performance will decrease due to scale and rust in the coolant system Mix the proper amount of coolant concentrate specified by the LLC manufacturer for the ambient temperature in which you will be operating LLC concentration should be between 30 and 60 Mixing different types of LLC i...

Page 24: ...n hole ø 10 H7 0 015 0 Depth 12 8 M10 Depth 15 ø 150 ø 260 21 5 4 P C ø 1 1 8 ø 95 0 0 035 Detail of front coupling 6 M10 Depth 20 Direction of rotation Center of crank shaft 285 1071 1300 4 786 740 5 256 5 Engine oil filters Fuel filter Fuel outlet ø 9 ø 16 fuel hose Fuel inlet ø 9 ø 16 fuel hose 2 321 5 170 Center of crank shaft Center of gravity NOTES 1 Drawing Shows mounting blocks at original...

Page 25: ...wings 12 05 6LY3 Service Manual 3 11 2007 Yanmar Marine International 6LY3 ETP Figure 3 7 Figure 3 7 000633 Diesel fuel piping Diesel fuel Diesel fuel S S Engine coolant pump Engine Engine Coolant Piping Engine seawater Piping NOTES S Engine Engine ...

Page 26: ... regulations they comply with EPA Emission Labels and Location Figure 3 8 Figure 3 8 0006259 THIS ENGINE IS CATEGORIZED AS A RECREATIONAL MARINE ENGINE UNDER 40 CFR PART 94 INSTALLATION OF THIS ENGINE IN ANY NONRECREATIONAL VESSEL IS A VIOLATION OF FEDERAL LAW SUBJECT TO CIVIL PENALTY Recreational marine engine label Emission control label REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONSANDA...

Page 27: ...wn EPA Guarantee Conditions for Emission Standard In addition to making sure that these conditions are met check for any deterioration that may occur before the required periodic maintenance times 1 Fuel The diesel fuel ASTM D975 No 1 D or No 2 D equivalent Cetane No 3 45 minimum 2 Oil API grade class CD 6 YDX M 5 81 D 6 H Method of air aspiration Number of cylinders Combustion chamber design Disp...

Page 28: ...igure 3 10 shows the location of the engine nameplate Figure 3 10 Figure 3 10 REDUCTION AND REVERSING GEAR Refer to your Marine Gear Service Manual for inspection disassembly and reassembly information Gear Model ENG No Model min 1 min 1 min 1 Continuous power kW Speed of prop shaft Fuel stop power kW 119175 7202 0006420 ...

Page 29: ...3 in Displacement 5 813 L 6 14 qt Continuous Rating Output Output at Crankshaft Engine Speed 3198 rpm Notes 1 and 2 3198 rpm 436 hp Metric 321 kW 401 hp Metric 295 kW 345 hp Metric 254 kW Maximum Output Output at Crankshaft Engine Speed 3300 rpm Notes 1 and 2 3300 rpm 480 hp Metric 353 kW 441 hp Metric 324 kW 379 hp Metric 279 kW 40 C 104 F at fuel inlet temperature High Idling Note 3 3500 25 rpm ...

Page 30: ...in foot pound force per minute g gram gal gallon U S gal hr gallon U S per hour gal min gallon U S per minute GL gear lubricant hp horsepower metric hr hour ID inside diameter ID identification IDI indirect injection in inch inAq inches Aqueous water in Hg inches Mercury in lb inch pound J joule JASO Japanese Automobile Standards Organization K kelvin kg kilogram kgf cm2 kilogram force per square ...

Page 31: ... 45360 kg oz x 28 35000 kg kg x 2 20500 lb g x 0 03527 oz lbf x 4 4480 N lbf x 0 4536 kgf N x 0 2248 lbf N x 0 1020 kgf kgf x 2 2050 lbf kgf x 9 8070 N lb ft x 1 3558 N m lb ft x 0 1383 kgf m lb in x 0 1130 N m lb in x 0 0115 kgf m kgf m x 7 2330 lb ft kgf m x 86 8000 lb in kgf m x 9 8070 N m N m x 0 7376 lb ft N m x 8 8510 lb in N m x 0 1020 kgf m psi x 0 0689 bar psi x 6 8950 kPa psi x 0 0703 kg...

Page 32: ...GENERAL SERVICE INFORMATION Unit Conversions 3 18 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 33: ...uired EPA Maintenance 4 3 EPA Requirements 4 3 Inspection and Maintenance 4 3 Inspection and Maintenance of EPA Emission Related Parts 4 5 Periodic Maintenance Procedures 4 6 Inspect Before Starting 4 6 After Initial 50 Hours of Operation 4 8 Every 50 Hours of Operation 4 10 Every 250 Hours of Operation 4 15 Every 500 Hours of Operation 4 25 Every 1000 Hours of Operation 4 28 Every 2000 Hours of O...

Page 34: ...PERIODIC MAINTENANCE 4 2 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 35: ...ions such as rain wind or snow from damaging the engine DANGER 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 will cause illness or even death Yanmar Replacement Parts Yanmar recommends that using genuine Yanmar parts when ...

Page 36: ... Hours or 4 Years Every 2000 Hours or 8 Years Whole Visually inspect the engine Fuel System Check the fuel level Drain the fuel tank Drain the filter and the water separator Replace the filter element Check the injection spray pattern Initial Overhaul the fuel feed pump Replace the fuel hoses Every two years or 2 000 hours of operation Lubricating System Check the oil level Crankcase Change the oi...

Page 37: ...blower Flush the intercooler Electrical System Check the alarm indicators Check the electrolyte level in the battery Adjust the tension of the alternator driving belt Check the wiring connections Cylinder Head etc Check for engine fluid leaks After starting Retorque all major nuts and bolts Adjust the intake exhaust valve clearance Initial Miscellaneous Items Check the electronic control system In...

Page 38: ... necessary Check the Engine Oil Level Crankcase 1 Check the engine oil level with the dipstick Figure 4 1 3 Insert the dipstick fully to check the level Figure 4 1 Figure 4 1 1 Rocker Arm Cover 2 Oil Filler Cap Yellow 3 Dipstick 4 Upper Limit 5 Lower Limit The oil should not be dirty and should have appropriate viscosity No coolant or diesel fuel should be present The level should be between the u...

Page 39: ...ediately with clean water Figure 4 3 Figure 4 3 1 Coolant Recovery Tank Cap 2 LOW Mark 3 FULL Mark 4 Coolant Recovery Tank 3 Replenish engine with coolant If the fluid level in the coolant recovery tank is lower than the LOW mark open the filler cap and check the coolant level in the engine coolant tank WARNING NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant w...

Page 40: ...em Make sure that the control lever can be operated smoothly before starting the engine If it feels heavy to manipulate or binds up in any way consult your Yanmar dealer or distributor Be sure to check the following after initial 50 hours or one month of operation whichever comes first Replace the Engine Oil and Engine Oil Filter Check the Electronic Control System Operation Adjust the Propeller S...

Page 41: ...ic Control System The electronic governor of the engine and the marine gear are connected to the control head switch panel and display through the Interface Module by wiring harnesses and terminal connectors The wiring terminals may become loose after long hours of use It is dangerous to operate under these conditions Check the wiring periodically 1 Check the wiring harness and connectors for the ...

Page 42: ...fuel water separator and drain off any water and dirt NOTICE If nothing drips when the drain plug is opened loosen the air bleed bolt Figure 4 6 1 on the top of the fuel water separator by turning counterclockwise 2 to 3 turns After draining be sure to tighten the air bleed bolt Air may bleed back into the system because the fuel water separator position is higher than the fuel level in the fuel t...

Page 43: ...r bleeding is required for normal engine operation Check the Battery Electrolyte Level WARNING ALWAYS turn off the battery switch or disconnect the negative cable before inspecting the electrical system Failure to do so could cause short circuiting and fires Always disconnect the negative battery cable first An accidental short circuit may cause damage fire and or personal injury ALWAYS connect th...

Page 44: ...4 Grease Testing Battery Charge Use a battery tester Figure 4 9 1 or hydrometer to check battery condition If the battery is discharged recharge it Measuring Battery Charge With Battery Tester Figure 4 9 Figure 4 9 1 Battery Tester Measurement with a Battery Tester When checking the battery with the battery tester connect the red clip of the tester to the positive battery terminal and black clip t...

Page 45: ... Battery Appearance Replace the battery if cracked or deformed Clean with fresh water if contaminated Figure 4 10 Figure 4 10 1 Float Hydrometer Parts Figure 4 11 Figure 4 11 1 Rubber Bulb 2 Glass Tube 3 Float How to Read a Hydrometer Figure 4 12 Figure 4 12 Specific Gravity and Remaining Battery Charge Specific Gravity 20 C 68 F Discharged Quantity of Electricity Remaining Charge 1 28 0 100 1 26 ...

Page 46: ...and possible damage to the bearing of the freshwater pump and the alternator 1 Make sure engine is not running 2 Check the tension of the V belts by pressing on the middle of a belt with your finger approximately 98 N 22 lb New V Belt refers to a V Belt which has been used less than 5 minutes on a running engine Used V belt refers to a V belt which has been used on a running engine for more than 5...

Page 47: ...rcooler Check the Wiring Connectors Tighten All Major Nuts and Bolts Check or Replace the Flexible Engine Mounts Replace the Engine Coolant Check the Fuel Injector Spray Pattern NOTICE This engine applies double spring nozzles manufactured by DENSO Testing modifications or repairs should be performed by your authorized YANMAR service center WARNING Never point a fuel injector toward you Since the ...

Page 48: ...igure 4 14 1 Nozzle Holder Retaining Nut 2 Nozzle Assembly 3 Nozzle Body 4 Needle Tip 5 Adjusting Shim 6 Tip Packing 7 Straight Pins 8 No 2 Pressure Spring Seat 9 No 2 Pressure Spring 10 Adjusting Shim 11 No 1 Pressure Spring Seat 12 Pressure Pin 13 No 1 Pressure Spring 14 Adjusting Shim 15 Nozzle Holder Body 0006171 10 11 12 13 14 15 3 2 5 6 7 8 9 1 4 ...

Page 49: ... times as quickly as possible to discharge foreign matter from the injection hole Figure 4 16 Figure 4 16 c Slowly pump the tester handle and observe the pressure gauge d Read the pressure gauge when the injection pressure begins to decrease If No 1 opening pressure is out of limits measure it precisely at an authorized FIE Fuel Injection Equipment service shop or replace the nozzle NOTICE Only No...

Page 50: ...to result Adjust Intake Exhaust Valve Clearance Take measurements and make adjustments while the engine is cold 1 Valve clearance measurement a Remove the rocker arm cover b Turn the crankshaft in the direction of normal rotation to bring the piston of the No 1 cylinder to its compression top dead center TDC while adjusting the index mark Figure 4 20 2 of the flywheel housing Figure 4 20 1 and the...

Page 51: ...ers in the order of ignition by turning the crankshaft 120 each time NOTICE Firing Order is 1 4 2 6 3 5 2 Valve Clearance Adjustment a Loosen the adjusting bolt of the valve bridge Figure 4 22 1 Loosen the locknut of the valve bridge adjusting bolt more than one turn to give clearance between the adjusting bolt and valve Check the valve for any inclination of valve cap or wear Figure 4 22 Figure 4...

Page 52: ... No 2 cylinder in the normal firing order The cylinder to be adjusted first does not have to be the No 1 cylinder Select and adjust the cylinder nearest to top dead center TDC and adjust other cylinders in the firing order of the engine by turning the crankshaft 120 each time Drain the Fuel Tank Open the drain cock of the fuel tank Inspect for water dirt or other sediment Drain water debris etc fr...

Page 53: ...p and down 4 Allow the fuel and air bubbles to flow from the air bleed bolt hole When the fuel no longer contains bubbles tighten the air bleed bolt This completes the air bleeding of the fuel system Start the engine 5 Repeat steps 1 through 4 if necessary 6 After engine start up the automatic air bleeding device purges the air from the fuel system No manual air bleeding is required for normal eng...

Page 54: ...Plug 3 Identification Label Figure 4 26 Figure 4 26 1 Zinc Anode Location 2 Heat Exchanger Clean the Air Intake Silencer Disassemble the intake silencer and clean the inside thoroughly 1 Remove the silencer by taking off the clamp 2 Clean the element with a neutral detergent 3 Reassemble after it is completely dry Clean the Exhaust Water Mixing Elbow The mixing elbow is attached to the turbocharge...

Page 55: ... drain plug Flush the Intercooler Rust and scale buildup in the intercooler can reduce engine performance by 10 Intercooler contamination causes the engine output to fall If a drop in engine output is noted by about 10 flush and clean the intercooler 1 Remove the cover on the flywheel end of the intercooler and inspect the inside of each tube for rust or scale buildup from seawater 2 If rust or sc...

Page 56: ...eze or antirust is added the coolant must be replaced periodically because it naturally degenerates 1 Place an approved container under the drain cocks 2 Open the two coolant drain cocks Figure 4 28 and completely drain all the coolant from the system Figure 4 28 Figure 4 28 1 Seawater Drain Cock 2 Coolant Drain Cock Figure 4 29 Figure 4 29 1 Freshwater Pump 2 Coolant Tank 3 Seawater Drain Cock 4 ...

Page 57: ...whichever comes first Replace the Seawater Pump Impeller Adjust the Propeller Shaft Alignment Check the V Belt Tension Inspect the Thermostat Replace the Exhaust Water Mixing Elbow Adjust the No load Minimum Speed Replace the Seawater Pump Impeller NOTICE The impeller must be replaced periodically every 500 hours or 2 years whichever comes first See Check the Seawater Pump Impeller on page 4 22 fo...

Page 58: ...FF LANGUAGE DAMPING 0006196 BACK i5601E Digital Display Alarms Engine Diagnostic Codes Performs the function indicated by a pop up menu if present With no pop up menu showing briefly press to display the Lighting Contrast menu With no pop up menu showing press and HOLD to display the MAIN MENU Buttons Down Arrow moves menu selection down Up Arrow moves menu selection up Right Arrow acts on current...

Page 59: ...yed on the digital display screen To acknowledge this warning press and hold the 5 right most button on the i5601E digital display for a few seconds until the main menu is displayed Use the down arrow button to move the cursor to Calibration Press the right arrow button then go to User Setting menu The arrow should be at the Reset Maint Time selection Press the right arrow key to reset The warning...

Page 60: ...line 1 Check the rubber hoses and clamps and replace if necessary 2 If trash scale or rust is found in heat exchangers clean them See Inspect the heat exchanger and pressure cap See Heat Exchanger Components and Functions on page 7 13 on page 4 30 Replace the V Belt Replace the alternator drive belt every 1 000 hours or 4 years whichever comes first See Adjust the V Belt Tension or Replace V Belt ...

Page 61: ...1 Block the priming pump with your finger and check whether the pressed in piston returns by spring force If the piston returns the piston does not have enough negative pressure Replace the priming pump as a set 2 Check the piston spring for cuts cracks uneven wear and rust 3 If the piston inter spindle or tappet assembly is extremely worn replace the part 4 Check the contact surface of the valve ...

Page 62: ... Systems Rust and scale are deposited inside the seawater and coolant systems during extended use This lowers coolant performance so it is necessary to clean and maintain the following parts in addition to replacing the coolant 1 Clean and inspect coolant rubber hoses Remove the coolant hoses for the closed coolant system and the seawater system Check for dirt buildup and other obstructions Clean ...

Page 63: ...with fresh water 5 Provide good ventilation in the engine room 6 Allow the engine to warm up before making any adjustments Engine Test Run 1 Start the engine and idle at 700 to 900 rpm for about 5 minutes 2 Check for any water diesel fuel or oil leakage Check for any abnormal vibrations or noises Check the oil pressure coolant temperature and exhaust gas color 3 Adjust the no load minimum and maxi...

Page 64: ...he intake exhaust valves fuel injection nozzle and cylinder head Do not raise the engine speed abruptly 3 Cruising Load Operation Do not operate the engine at full load yet but raise the speed gradually for about 10 min until it reaches the rated speed Make sure that the exhaust gas color and temperature are normal Check the instrument panel and see if the coolant temperature and oil pressure are ...

Page 65: ...om the negative battery terminal 6 Cover the silencer and electric parts with a waterproof cover to prevent water and dirt from entering 7 Select a well ventilated location without moisture and dust for storage 8 Recharge battery once a month during storage to compensate for self discharge 9 When storing an engine for a long time run the engine periodically according to the following procedure bec...

Page 66: ...PERIODIC MAINTENANCE Periodic Maintenance Procedures 4 34 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 67: ... 5 19 Removing the Intercooler 5 19 Removing the Starter Motor 5 20 Removing the Alternator 5 20 Removing the Coolant Tank Cooler and Pump 5 20 Removing the Seawater Pump 5 20 Removing the Oil Filter and Oil Cooler 5 20 Removing the Electronic Control Devices 5 20 Removing the Fuel Injection Lines 5 20 Removing the Fuel Injection Nozzles 5 21 Removing the Fuel Injection Pump 5 21 Removing the Rock...

Page 68: ...2 Inspecting the Flywheel and Housing 5 53 Replacing the Ring Gear 5 53 Positioning Top Dead Center 5 53 Inspecting the Intake Exhaust System 5 54 Assembling the Engine and Components 5 55 Precautions Before Assembling the Engine 5 55 Installing the Tappets 5 55 Installing the Piston Cooling Nozzles 5 56 Installing the Camshaft Bearings 5 56 Installing the Crankshaft 5 57 Installing the Oil Pump 5...

Page 69: ... Installing the Crankshaft V Pulley and Damper 5 67 Installing the Fuel Injection Nozzles 5 68 Installing the Heat Exchanger 5 70 Installing the Coolant Tank 5 70 Installing the Engine Oil Cooler 5 71 Installing the Engine Oil Filters 5 71 Installing the Engine Coolant Hoses 5 72 Installing the Engine Air Ducts 5 74 Installing the Engine Turbocharger 5 74 Installing the Mixing Elbow 5 75 Installin...

Page 70: ...ENGINE 5 4 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 71: ...fety message describes a hazardous situation which if not avoided could result in death or serious injury ALWAYS ensure that all connections are tightened to specifications after repair is made to the exhaust system All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning INTRODUCTION This section of the Ser...

Page 72: ...ions Before Engine Disassembly Diagnose the cause of the trouble and disassemble only those parts which are necessary Keep all disassembled parts in order Have all required tools on hand Clean parts with an approved cleaner in a suitable location Clear an adequate area for parts and prepare a container Drain coolant seawater and oil Close the seacock ...

Page 73: ... reassembling the engine Please use them as instructed General Hand Tools Part Name Part No FIC Lock Bolt 158908 51490 FIC Lock Bolt Collar 158908 51480 Name of the Tool Illustration Remarks Wrench Size 10 x 13 12 x 14 17 x 19 22 x 24 Screwdriver Steel Hammer Local Copper Hammer Local Mallet Local Nippers Local Pliers Local 0005719 0005720 0005721 0005722 0005723 0005724 0005725 ...

Page 74: ...Yanmar Marine International Offset Wrench Local 1 set Box Spanner Local 1 set Scraper Local Lead Rod Local File Local 1 set Rod Spanner for Hexagon Socket Head Bolts Local Size 6 mm 8 mm 10 mm Name of the Tool Illustration Remarks 0005726 0005727 0005728 0005729 0005730 0005731 ...

Page 75: ...stration Remarks Piston Pin Insertion Extraction Tool A B C D 11 mm 0 433 in 20 mm 0 787 in 80 mm 3 149 in 35 mm 1 377 in Connecting Rod Small End Bushing Insertion Extraction Tool A B C D E F 40 mm 0 2 mm 0 5 mm 1 574 in 0 007 in 0 019 in 86 mm 3 385 in 24 mm 0 944 in 37 mm 0 45 mm 0 48 mm 1 456 in 0 017 in 0 018 in 5 8 0 5 mm 0 228 in 0 019 in 10 30 0005733 A B C D Extraction of the piston pin I...

Page 76: ...raction Tool A B C D 7 5 mm 0 295 in 20 mm 0 787 in 75 mm 2 952 in 11 mm 0 433 in Oil Filter Wrench Piston Ring Compressor Piston Ring Tool For removal insertion of the piston ring Valve Lapping Tool Rubber Cap Type Valve Lapping Powder Name of the Tool Illustration Remarks 0005733 A B C D 0005737 0005738 0005739 0005740 0005741 0005742 0005743 ...

Page 77: ...005745 Local 0005746 0005747 Name of the Tool Illustration Remarks Stem Seal Insertion Tool For inserting the stem seal d1 d2 d3 L1 L2 L3 Intake 16 2 mm 0 637 in 22 mm 0 866 in 13 5 mm 0 531 in 11 5 mm 0 452 in 65 mm 2 559 in 4 mm 0 157 in Exhaust 16 2 mm 0 637 in 22 mm 0 866 in 13 5 mm 0 531 in 9 5 mm 0 374 in 65 mm 2 559 in 4 mm 0 157 in L2 L1 d1 d2 0005748 L2 L1 L3 d1 d2 d3 0005749 ...

Page 78: ...ers 0 150 mm 5 905 in Micrometer 0 25 mm 0 1 in 25 50 mm 1 2 in 50 75 mm 2 3 in 75 100 mm 3 4 in 100 125 mm 4 5 in 125 150 mm 5 6 in Cylinder Gauge 18 35 mm 0 708 1 377 in 35 60 mm 1 377 2 362 in 50 100 mm 1 968 4 in Thickness Gauge 0 05 2 mm 0 001 0 078 in Torque Wrench 0 343 N m 0 35 kgf m 0 252 lb ft Nozzle Tester 0 49 MPa 0 500 kgf cm2 0 7106 psi 0005750 0005751 0005752 0005753 0005754 0005755...

Page 79: ...tic Stand Keeps the dial gauge firmly in position 4 Micrometer Measures the outer diameter of the crankshaft piston piston pin etc 5 Cylinder Gauge Measures the inner diameter of the cylinder liner and rod bearings 6 Vernier Calipers Measures the various outer diameter thickness and width 7 Depth Micrometer Measures the valve sink 8 Square Measures the distortion in the position of the springs and...

Page 80: ...t at the time of assembly 12 Radiator Cap Tester Checks for leaks in the freshwater system 13 Battery Current Tester Checks the density of antifreeze and charging condition of battery fluid 14 Nozzle Tester Checks the shape and pressure of spray emitted from the fuel injection valve at the time of injection 15 Digital Thermostat Measures the temperature of various parts No Name of the Tool Use Ill...

Page 81: ...the rotation speed by using a reflector seal which is placed on the exterior of the revolving shaft High Pressure Fuel Pipe Clamp Type Measures the rotation speed without reference to the revolving shaft center or the exterior of the revolving shaft 17 Circuit Tester Volt Ohm Meter VOM Measures the resistance voltage and continuity of the electric circuit No Name of the Tool Use Illustration 00057...

Page 82: ... g 1 7 oz Excellent adhesive strength locks the bolt semi permanently Seal Tape 5 m 16 ft round tape Sealing material for the threaded parts of various pipes Ambient temperature range 150 to 200 C 238 to 392 F EP Lubricant Molybdenum Disulfate Brand Name LOWCOL PASTE 50 g 1 7 oz For assembly of engine cylinders pistons metals shafts etc Spray type facilitates application work Brand Name PASTE SPRA...

Page 83: ...ffective 4 When gaskets are used do not use sealant Three Bond TB1212 Figure 5 1 Figure 5 1 1 Oil Pan Mating Surface 2 Inside of Oil Pan 3 Bead of Three Bond TB1212 4 Outside Cleaning Agent for Turbocharger 4 L 1 gal x 4 Special cleaning agent that requires no water specially designed for blower of turbocharger and intercooler 18 L 5 gal x 1 15 sets 1 500 cc 1 pt x 6 Items Usual Contents Features ...

Page 84: ...body fit reamer bolts and disassemble the propeller shaft coupling and thrust shaft coupling 9 Disassemble the PTO coupling from the front of the engine if installed 10 Remove the flexible mount nuts Lift the engine and remove it from the engine base Leave the flexible mount attached to the engine base Draining the Coolant 1 Open the two seawater drain cocks Figure 5 2 1 and 3 to drain the seawate...

Page 85: ...Mixing Elbow 1 Remove the seawater hose connected to the mixing elbow Figure 5 4 4 2 Remove the mixing elbow from the turbocharger Removing the Turbocharger 1 Remove the intake pipe turbine intake manifold 2 Remove the turbine oil return line from the oil pan side of the engine that goes to the oil pan 3 Remove the turbine oil line oil cooler turbine 4 Remove the turbine Removing the Coolant Hoses...

Page 86: ...ump 1 Remove the coolant tank Figure 5 7 1 and gasket Figure 5 7 Figure 5 7 1 Coolant Tank 2 Dipstick 3 Heat Exchanger 4 Seawater Pump 2 Remove the heat exchanger Figure 5 7 3 3 Remove the coolant pump and gasket Removing the Seawater Pump Remove the seawater pump Figure 5 7 4 Removing the Oil Filter and Oil Cooler 1 Remove the oil filter Figure 5 5 2 2 Remove the oil cooler Figure 5 5 1 3 Remove ...

Page 87: ...om the drive shaft housing Removing the Flywheel and Flywheel Housing 1 Loosen the flywheel bolts and remove the flywheel 2 Remove the flywheel housing NOTICE Avoid scratching the ring gear Turning the Engine Block Over Place wooden blocks on the floor Set the mating surface of the cylinder block on the wood Keep the positioning pins clear Removing the Oil Pan and Spacer Remove the oil pan and spa...

Page 88: ... End 7 40 mm 1 574 in Plug 8 16 mm 0 629 in Plug 9 40 mm 1 574 in Plug Dye Penetrant Inspection Procedure The dye penetrant inspection kit consists of an aerosol cleaner penetrant and developer Figure 5 10 Figure 5 10 NOTICE Always read the instructions included with the dye penetrant kit before use 1 Spray the cleaner directly on the surface to soften heavily soiled areas or wipe the area with a ...

Page 89: ...ug Tap lightly with a hammer and remove the plug Screwdriver Hammer 2 1 Clean and Apply Adhesive Wipe the cylinder block and plug opening clean Apply an adhesive agent acrylic on the outside surface of the plug and cylinder block opening Thinner Adhesive agent or Three Bond 1386B 3 1 Jig Insert the plug using a driver and hammer Drive the plug straight into the opening Driver Hammer 4 Do not add c...

Page 90: ...ylinder bore Figure 5 13 Figure 5 13 1 20 mm 0 787 in Below Top of Cylinder Bar 2 Center of Piston Travel 3 20 mm 0 787 in from Bottom of Piston Skirt 4 Measure in Both Directions 4 at Points 1 2 and 3 5 Measure in Both Directions 5 at Points 1 2 and 3 Measure at the center of piston travel Figure 5 13 2 Measure at 20 mm 0 787 in Figure 5 13 3 from the bottom of the piston skirt in directions 4 an...

Page 91: ...iddle of the cylinder bore 3 Two measurements at position 3 at the bottom of the piston ring travel in the cylinder bore This produces six different measurement values Calculate the average value of all the measurements for each cylinder bore and compare with the wear limits See Measuring Cylinder Bore Diameters on page 5 25 Measuring Cylinder Bore Diameters Measure the cylinder bore diameters and...

Page 92: ... The head contains six cylinder bores and is installed with 26 head bolts The valve seats are treated with a special satellite alloy for superior resistance to heat and wear The areas between the intake exhaust valves are cooled with internal circulating water Figure 5 14 Figure 5 14 0005596 3 4 5 6 7 8 9 10 11 12 18 19 20 21 22 13 14 15 16 17 1 2 ...

Page 93: ...rm Cover 4 Breather Hose from Drive Shaft Housing 5 Baffle Plate 6 Rocker Arm Shaft 7 Exhaust Rocker Arm 8 Rocker Arm Spring 9 Intake Rocker Arm 10 Bridge Seat 11 Rocker Arm Support 12 Valve Bridge 13 Valve Keepers 14 Valve Retainer 15 Valve Spring 16 Valve Stem Seal 17 Valve Guide 18 Bridge Guide 19 Water Pump End 20 Intake Valve 21 Exhaust Valve 22 Cylinder Head ...

Page 94: ...earance between the straight edge and mating surface with a feeler gauge Figure 5 15 Figure 5 15 2 Check for cracks in the cylinder combustion surfaces Remove the fuel injection nozzle intake and exhaust valve Check for discoloration or distortion Perform a dye penetrent inspection to check for any cracks Figure 5 16 Figure 5 16 3 Check the intake and exhaust valve seats Check the surface and widt...

Page 95: ...rd dimension 45 using a grinding wheel with a 15 chamber NOTICE When seat adjustment is necessary check the valve and valve guide If the clearance exceeds the tolerance replace the valve or the valve guide and grind the seat Figure 5 19 Figure 5 19 1 Valve Seat Width 2 Valve Seat 3 Knead valve compound with oil and finish the valve seat Figure 5 19 2 with a lapping tool NOTICE Use a rubber cap typ...

Page 96: ...pleted Replace the valve and valve seat if they exceed tolerances Figure 5 21 Figure 5 21 Inspecting Intake Exhaust Valves and Valve Guides Check for Wear and Corrosion of Each Valve Stem Measure the outside diameter of valve Figure 5 23 stem Replace the valve if the stem is excessively worn or corroded Figure 5 22 Figure 5 22 Figure 5 23 Figure 5 23 0005602 Intake Valve Stem Outside Diameter Stan...

Page 97: ...asure the inside diameter of the valve guide and compare it to the Valve Guide Specifications Chart below Replace the valve guide if it exceeds the wear limit NOTICE The inside diameter standard dimensions are measured after the guide is installed in the cylinder head Replacing the Valve Guide Use the valve guide insertion tool Figure 5 25 1 and tap valve guide Figure 5 25 2 into the cylinder head...

Page 98: ...ace a tool stop against the cylinder head over the valve stem Figure 5 27 1 2 Place the valve stem seal Figure 5 27 4 on the guide pin Figure 5 27 2 3 Place the guide pin and seal on the valve stem Check that the spring Figure 5 27 3 is still in position on the seal 4 Use the valve stem seal installer tool to install the seal Tap the seal in position using a tool stop Figure 5 27 6 to prevent dama...

Page 99: ...prings The side with the smaller pitch painted yellow Figure 5 31 2 should face down toward the cylinder head NOTICE The pitch of this valve spring is not even Pay attention to the up down direction of the spring when assembling Figure 5 31 Figure 5 31 1 Top 2 Small Pitch Side Yellow 3 Down Side Valve Spring Inclination Limit 1 2 mm 0 047 in Valve Spring Standard Limit Free Length 53 0 mm 2 086 in...

Page 100: ...ing retainer and spring cotters when the contact area is less than 70 or when the spring cotters have worn excessively Inspecting the Injection Nozzle Sleeves Lubricate the nozzle O rings Figure 5 32 1 with clean engine oil Insert the nozzle sleeve Figure 5 32 2 into the cylinder head and torque to the value shown below Figure 5 32 Figure 5 32 1 O Ring 2 Nozzle Sleeve 3 M13 4 Gasket Nozzle Sleeve ...

Page 101: ...nd press the fuse wire between the piston and head Remove the head and take out the compressed fuse wire Measure the thickness of the compressed fuse wire at four positions and calculate the average top clearance for each piston Figure 5 34 Figure 5 34 1 Fuse Wire Inspecting the Intake Exhaust Rocker Arms Excessive wear of the rocker arm bearings and rocker arms will affect the duration and timing...

Page 102: ...s and Piston Pins Pistons are made of a special light alloy with superior thermal expansion characteristics The top of the piston forms a swirl type combustion chamber The inside surface of the piston face is cooled with oil jet lubrication NOTICE Piston shape differs among engine models If an incorrect piston is installed engine performance will be reduced Check the applicable engine model identi...

Page 103: ...cording to the table below The size mark of a piston is shown on its top surface The size mark of a cylinder sleeve is shown on the non operating side of the cylinder block The serviceable matches of pistons and sleeves are as provided below Piston Outside Diameter Piston ID Mark Standard Limit Clearance Between Piston and Cylinder L 105 799 105 809 mm 4 1653 4 1656 in 105 780 mm 4 1645 in 0 111 0...

Page 104: ...ns a b and c in directions A and B Figure 5 41 Figure 5 41 1 Piston Pin Outside Diameter Measuring the Piston Rings There are two compression rings and one oil control ring Figure 5 42 Figure 5 42 1 Top Compression Ring 2 Middle Compression Ring 3 Oil Control Ring Measure the thickness and width of the rings Measure the ring to groove clearance after installing the ring on the piston Replace if we...

Page 105: ...up Figure 5 45 Figure 5 45 Piston Rings Standard Limit Top Ring Groove Width 2 626 2 646 mm 0 1033 0 1041 in 2 746 mm 0 1081 in Ring Width 2 470 2 490 mm 0 0972 0 0980 in 2 450 mm 0 0964 in Clearance Second Ring Groove Width 2 570 2 585 mm 0 1011 0 1017 in 2 140 mm 0 0842 in Ring Width 2 470 2 490 mm 0 0972 0 0980 in 1 950 mm 0 0767 in Clearance 0 080 0 115 mm 0 0031 0 0045 in 0 200 mm 0 0078 in O...

Page 106: ...ression Ring Gap 5 Oil Control Ring Gap 6 Middle Compression Ring Gap 7 Direction of Piston Pin 8 Direction of Side Pressure Stagger the piston rings at 120 intervals making sure none of them line up on the piston The oil control ring is equipped with a coil expander The coil expander joint Figure 5 47 2 should be opposite staggered 180 the oil ring gap Figure 5 47 1 Figure 5 47 Figure 5 47 1 Gap ...

Page 107: ...Rod 2 Piston Pin Bearing 3 Crank Pin Bearing Inserts 4 Connecting Rod Cap 5 Connecting Rod Cap Bolts Inspecting the Connecting Rod Bearing Alignment Ensure that the connecting rod is not twisted Insert the appropriate mandrel Figure 5 49 3 into both ends of the connecting rod Figure 5 49 Figure 5 49 1 Parallel Measurement 2 Twist Measurement 3 Mandrel Measure alignment Replace connecting rod if it...

Page 108: ...de diameter Replace the crank pin bearing if the oil clearance exceeds the stated limits Correct the crankshaft by grinding to a uniform undersized dimension if available Use an oversized bearing insert in the connecting rod if available Figure 5 52 NOTICE When measuring the inside diameter of connecting rod bearing inserts install the bearing inserts correctly and tighten the connecting rod cap b...

Page 109: ...large end of the connecting rod and install the crankshaft bearing inserts Check that the bearing inserts fit properly Match the alignment marks Figure 5 54 1 on the rod cap and connecting rod Figure 5 54 Figure 5 54 1 Alignment Mark 2 Index Mark Coat the threads of the cap bolts with engine oil Install the connecting rod to the crankshaft and tighten the bolts to the specified torque If a torque ...

Page 110: ... pins and crank journals have been induction hardened for superior durability The crankshaft Figure 5 56 2 is designed with balance weights Figure 5 56 1 for minimum vibration The crankshaft main bearings Figure 5 56 3 are the hanger type The upper bearing insert cylinder block side is designed with an oil groove There is no oil groove on the lower bearing insert bearing cap side The main bearing ...

Page 111: ...her significant damage is found Figure 5 57 Figure 5 57 Inspecting the Crankshaft Bend and Deflection Support the crankshaft on V blocks at both ends main bearing journals Rotate the crankshaft and measure the deflection Figure 5 58 1 of the center journal with a dial indicator Figure 5 59 1 Figure 5 58 Figure 5 58 1 Deflection 2 Bend Figure 5 59 Figure 5 59 1 Dial Indicator Compare reading with s...

Page 112: ... engine block Tighten the main bearing caps to the specified torque Move the crankshaft along its horizontal axis from end to end Install a dial indicator Figure 5 62 1 on one end of the crankshaft to measure crankshaft end play Figure 5 62 Figure 5 62 1 Dial Indicator Replace the thrust bearing if it is worn beyond the stated limit Crankshaft Pin and Main Bearing Journals Item Limit Diameter Roun...

Page 113: ...e 5 Main Bearing Cap Intermediate 6 Main Bearing Cap Bolt 7 Main Bearing Cap 5 Tighten the cap to the specified torque 6 Measure the inner diameter of the main bearing inserts NOTICE When assembling the bearing cap keep the following in mind 1 The lower bearing insert cap side has no oil groove 2 The upper bearing insert block side has an oil groove 3 Check the cylinder block alignment number 4 Th...

Page 114: ...Camshaft Bearing 5 Thrust Bearing 6 Camshaft Gear Inspecting the Camshaft Side Clearance NOTICE Measure the thrust clearance before disassembling The cam gear Figure 5 65 1 and camshaft are assembled using a shrink fit Use caution when replacing the cam thrust bearing Figure 5 65 Figure 5 65 1 Cam Gear 2 Thrust Metal 3 Side Clearance Measure the height of each cam lobe as shown in Figure 5 66 Figu...

Page 115: ...camshaft on V blocks Place a dial indicator at the central bearing area Figure 5 67 1 and rotate the camshaft on the V blocks Figure 5 67 Figure 5 67 1 Central Bearing Measure for variations Replace camshaft if it measures beyond the stated limits NOTICE The reading on the dial indicator is divided by two to determine the camshaft bend Intake Cam Height Standard Limit 49 435 49 565 mm 1 9462 1 951...

Page 116: ...t The tappet for the intake valve has no notch Check the contact area of each tappet Replace if excessively or unevenly worn Figure 5 70 Figure 5 70 1 Abnormal Contact Area 2 Normal Contact Area Measure the outer diameter of the tappet Figure 5 71 Replace if worn beyond the stated limits Figure 5 71 Figure 5 71 0005654 1 1 0005655 1 0005653 1 2 Tappet Specifications Standard Limit Tappet Stem Outs...

Page 117: ... injection timing and a decrease in engine performance Inspecting the Idler Gear The idler gear bearing is a press fit in the gear Measure the bearing Figure 5 73 2 inner diameter Measure the outer diameter of the idler gear shaft Figure 5 73 3 Replace the bearing and or idler gear shaft if the oil clearance exceeds the stated limit Figure 5 73 Figure 5 73 1 Idler Gear 2 Idler Gear Bearing 3 Idler...

Page 118: ...g the Gear Timing Marks Align the timing marks as shown in Figure 5 74 on each gear when assembling the gear train A B and C Figure 5 74 Figure 5 74 1 Fuel Injection Pump Gear 2 Camshaft Gear 3 Seawater Pump Gear 4 Idler Gear 5 Crankshaft Gear 6 Oil Pump Gear 0005659 A C C A B 1 2 3 4 5 6 4 2 5 0005660 1 2 3 4 5 6 1 4 ...

Page 119: ...otor pinion The stamped letter and line which show top dead center of each cylinder are positioned on the flywheel circumference By matching these marks with the arrow mark at the hole of the flywheel housing the rotary position of the crankshaft can be ascertained in order to adjust tappet clearance or fuel injection timing Replacing the Ring Gear Heat the ring gear evenly at its circumference Us...

Page 120: ...ylinder head when assembling Ensure there is no air leak NEVER operate an engine with the intake air silencer removed Exhaust System Components Exhaust gas Figure 5 78 4 and 5 enters the turbocharger Figure 5 78 6 through the exhaust manifold Figure 5 77 1 in the coolant tank which is installed on the cylinder head Figure 5 77 2 The exhaust gas flows to the mixing elbow Figure 5 78 2 through the t...

Page 121: ...es where required Clean all parts with an approved cleaning solvent diesel fuel or inspect all engine parts and compare with stated wear limits NOTICE If dirt shavings and other debris are allowed to remain in the engine seizure premature wear intermittent failures and poor engine performance may result Completely clean each oil hole After cleaning check that no scaling remains anywhere on the cyl...

Page 122: ...Nozzle Installing the Camshaft Bearings 1 Apply oil to the outer surface of each bearing Figure 5 82 1 and mounting surface of the cylinder block and then press the bearing into its position using a driving tool Check the position of each oil hole More than 2 3 area of a hole should be aligned Forward A 2 Middle A 1 5 Aft A 0 5 Figure 5 82 Figure 5 82 1 Bearing 2 After installation check each bear...

Page 123: ...der Block Figure 5 84 Figure 5 84 2 Lubricate each crank pin and crank journal Set each journal in the main bearing of the block 3 Lubricate both surfaces of each cap side main bearing and install each main bearing insert to the cap 4 Oil the bolt holes of each bearing cap Install bearing caps Figure 5 85 2 Tighten each cap bolt to the specified torque value NOTICE Check that the arrow mark Figure...

Page 124: ...igure 5 87 Figure 5 87 1 Oil Pump Idler Gear 2 Install the oil pump Figure 5 88 1 with the position pin Secure the pump by tightening three M10 x 55 mm bolts to the specified torque value Figure 5 88 Figure 5 88 1 Oil Pump 3 Measure the gear backlash between the oil pump and idler gear and compare to the value specified below End Play of the Crankshaft 0 132 0 223 mm 0 0051 0 0087 in Oil Pump Idle...

Page 125: ...Check end play of the camshaft NOTICE If the cam gear is removed from the camshaft place thrust bearing before installing the gear Heat the cam gear to between 180 C 356 F and 200 C 392 F press it in place Interference 0 023 to 0 060 mm Installing the Piston Assemblies 1 The piston and connecting rod should be assembled with the embossed connecting rod mark Figure 5 91 4 and the stamped FW mark Fi...

Page 126: ...is process for each piston Installing the Oil Pan Spacer Apply sealant to the oil pan spacer mating surface and then place the spacer Figure 5 92 1 to the cylinder block Figure 5 92 2 Secure the spacer with two M8 x 35 mm bolts and two M8 x 30 mm bolts Torque bolts to the specified value Figure 5 92 Figure 5 92 1 Spacer 2 Cylinder Block Installing the Oil Intake and Delivery Tubes 1 Fit the flange...

Page 127: ...ng the Flywheel Housing Oil Seal 1 Grease the outer circumference of the lip portion of the oil seal Figure 5 95 2 Figure 5 95 Figure 5 95 1 Cylinder Block 2 Oil Seal 2 Install the oil seal into the flywheel housing Installing the Flywheel Housing 1 Use the two pilot pins as a guide and fit the flywheel housing to the engine block Avoid damage to the oil seal 2 Secure the flywheel housing with nin...

Page 128: ... 2 Spindle Shaft 3 Oil Hole 2 Secure the idler gear shaft with two M8 x 25 mm bolts Tighten bolts to the specified torque values 3 Measure the side clearance and compare with the following specified value 4 Bring and hold the No 6 piston water pump end to top dead center TDC 5 Orient the idler gear Figure 5 99 3 as necessary to set the A Figure 5 99 2 between the two embossed marks on the crank ge...

Page 129: ... the coolant passage cover Figure 5 101 1 Figure 5 101 Figure 5 101 1 Coolant Passage Cover 2 Cylinder Block 2 Secure with bolts Installing the Fuel Injection Pump See Installing the Fuel Injection Pump on page 6 17 Installing the Flywheel 1 Use the pilot pin to orient the flywheel NOTICE Use two M10 x 1 5 mm bolts to help guide the flywheel Oil the threads and flanges 2 Secure the flywheel with s...

Page 130: ...ant Pump End 2 Operation Side 3 Flywheel End 4 Non Operation Side 6 Set do not drop 13 M14 x 149 mm head bolts into the holes on the non operation side Figure 5 104 4 of the engine Figure 5 104 7 Finger tighten all of the head bolts 8 Tighten the head bolts in the sequence shown in Figure 5 104 in three stages NOTICE Use the values for the new bolts or the used bolts 9 Tighten all the head bolts t...

Page 131: ...o the flywheel end Figure 5 106 4 of the cooler core and insert the core into the cooler body NOTICE Align marks of the core and the case Figure 5 107 Figure 5 106 Figure 5 106 1 O Ring 2 Coolant Pump End 3 Separator Packing 4 Flywheel End Figure 5 107 Figure 5 107 2 Apply silicone grease to the O rings fit two O rings to both sides of the cooler core and fit the side covers to the cooler 3 Fit th...

Page 132: ...ure valve clearances and ensure they fall within the following specifications Figure 5 109 Figure 5 109 1 Flywheel End 2 Coolant Pump End 3 Operating Side NOTICE Be sure the opening and closing angles for both intake and exhaust valves are checked when timing gear is disassembled Installing the Rocker Arm Cover 1 Coat all of the rocker arm cover bolts M8 x 25 mm with a liberal amount of clean engi...

Page 133: ... 2 on the coolant passage cover 4 Install and tighten the bolts to the specified torque value Installing the Drive Shaft Housing Cover 1 Apply the correct sealant to the mating surface of the drive shaft housing 2 Use the pilot pins to position the cover 3 Secure the cover with nine M8 x 45 mm washer based bolts Figure 5 111 1 and five M8 x 80 mm washer based bolts Figure 5 111 2 Figure 5 111 Figu...

Page 134: ... O ring Figure 5 114 3 to the fuel injection nozzle Figure 5 114 2 and apply oil to outside of the O ring NOTICE Replace the O ring every time the fuel injection nozzle is disassembled Figure 5 114 Figure 5 114 1 Fuel Nozzle Retainer 2 Fuel Injection Nozzle 3 O Ring 4 Nozzle Seat 2 Insert the nozzle seats Figure 5 114 4 into the cylinder head 3 Fit the fuel injection nozzle to the cylinder head NO...

Page 135: ...e Figure 5 116 3 and the retainer Figure 5 116 Figure 5 116 1 1 5 mm 0 059 in Gap 2 1 mm 0 039 in Gap 3 Fuel Nozzle 4 Retainer 5 Intake Rocker Arm 7 Insert the pipe seal Figure 5 117 1 for the fuel injector line Figure 5 117 3 into the cylinder head and connect the fuel injector line to the fuel injector nozzle Figure 5 117 2 Figure 5 117 Figure 5 117 1 Pipe Seal 2 Fuel Injector Nozzle 3 Fuel Inje...

Page 136: ...1 Notch in Core 2 Centering Hole 4 Fit the separator seal to both side covers water pump end and flywheel end See Figure 5 118 5 Fit the side cover to the heat exchanger Installing the Coolant Tank 1 Fit the O ring on the thermostat Figure 5 120 2 and insert the thermostat into the coolant tank Figure 5 120 1 Figure 5 120 Figure 5 120 2 Secure the coolant tank with bolts 3 Tighten the bolts to the...

Page 137: ...side cover 5 Install the end covers to the oil cooler 6 Install the oil cooler to the engine 7 Install the intercooler and the filter bracket to the engine 8 Install and tighten the oil tube Installing the Engine Oil Filters 1 Apply a light coat of engine oil to the rubber seal of both filters Figure 5 124 Figure 5 124 Figure 5 124 1 Full Flow Oil Filter 2 Oil Filter Bracket 3 Bypass Oil Filter 2 ...

Page 138: ...e heat exchanger 3 Use the proper sealant and install hose elbow B Figure 5 126 8 to the intercooler Figure 5 126 6 4 Use two hose clamps on each end of the hose and install the hose between the intercooler and heat exchanger 5 Install the hoses and clamps to the inlet and outlet of the heat exchanger Figure 5 126 2 and the oil cooler Figure 5 126 1 6 Install the hoses and clamps to the inlet and ...

Page 139: ...rnational Figure 5 126 Figure 5 126 1 Oil Cooler 2 Heat Exchanger 3 Hose Elbow A 4 Flow from the Seawater Pump 5 Flow to the Marine Gear 6 Intercooler 7 Flow from the Heat Exchanger 8 Hose Elbow B 9 Flow from the Marine Gear 10 Flow from the Intercooler to the Oil Cooler 0005828 2 3 1 4 6 10 5 8 7 9 ...

Page 140: ...127 7 by using the hose Figure 5 127 6 and the clamp Figure 5 127 5 Installing the Engine Turbocharger 1 Loosely assemble bracket A Figure 5 128 4 to bracket B Figure 5 128 5 using two M10 x 18 bolts Figure 5 128 Figure 5 128 1 Turbocharger 2 Mixing Elbow 3 Air Silencer 4 Bracket A 5 Bracket B 6 Flywheel Housing 2 Install and finger tighten the two M10 x 22 mm bolts in the engine 3 Install the tur...

Page 141: ...engine operation Figure 5 129 Figure 5 129 1 Turbocharger 2 Silencer 3 Flanges 5 Thoroughly degrease the silencer flange the inside of the hose and the turbocharger flange 6 Assemble the components and tighten the hose bands to the following specified torque value Installing the Mixing Elbow Install the mixing elbow Figure 5 130 4 to the turbocharger Figure 5 130 2 with the gasket Figure 5 130 1 a...

Page 142: ...line B Figure 5 131 2 at the timer inlet Installing the Alternator 1 Install the adjuster Figure 5 132 2 on the coolant pump Figure 5 132 1 Figure 5 132 Figure 5 132 1 Coolant Pump 2 Adjuster 3 Adjuster Bolt 4 Alternator 5 Check Tension 6 Deflection 8 10 mm approximately 3 8 in 7 V Belt 2 Torque the adjuster bolts Figure 5 132 3 to the specified values 3 Install the alternator Figure 5 132 4 4 Adj...

Page 143: ...on Nozzle Components and Functions 6 26 Fuel Injection Nozzle Functions 6 26 Fuel Feed Pump Components and Functions 6 28 Fuel Feed Pump Components 6 29 Fuel Feed Pump Specifications 6 30 Disassembling the Fuel Feed Pump 6 30 Inspecting the Fuel Feed Pump 6 30 Assembling the Fuel Feed Pump 6 30 Testing the Fuel Feed Pump 6 31 Fuel Filter Components and Functions 6 33 Inspecting the Fuel Filter 6 3...

Page 144: ...FUEL SYSTEM 6 2 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 145: ...el fuel or other flammable material near the engine during engine operation or shortly after shutdown Never use a shop rag to catch the fuel ALWAYS put an approved fuel container under the opening whenever removing any fuel system component such as changing the fuel filter Dispose of waste properly Wipe up all spills immediately Piercing Hazard Avoid skin contact with high pressure diesel fuel spr...

Page 146: ...e Manual 2007 Yanmar Marine International INTRODUCTION This section of the Service Manual describes the procedures necessary to remove install and adjust the injectors and their associated system components as used on the Yanmar 6LY3 engines ...

Page 147: ...t Close No 1 Plunger 2 5 mm 0 098 in 0 05 Delivery Valve Retraction Volume 0 mm3 st CPV 0 cu in Adaptive Cutting 0 mm 0 in Delivery Valve Opening Pressure 1 1 MPa 11 2 kgf cm2 159 441 psi Delivery Valve Spring Constant 24 8 N mm 2 525 kgf mm 5 5 lb ft Damping Valve Allowable Maximum Pump Speed 1850 rpm Overflow Pressure 0 2 MPa 2 0 kgf cm2 29 007 psi Allowable Fuel Pressure 100 MPa 1020 kgf cm2 14...

Page 148: ...l 2007 Yanmar Marine International Fuel System Diagram Figure 6 1 Figure 6 1 1 Fuel Nozzle 2 Fuel Return Line 3 Fuel Filter 4 Fuel Line to Tank 5 Fuel Feed Pump 6 Fuel Line from Tank 7 Fuel Injection Pump 8 Fuel Injection Line 3 4 1 8 7 6 5 2 0005665 ...

Page 149: ...2 2 Figure 6 2 Figure 6 2 1 Fuel Injection Pump 2 Electro Hydraulic Timer 3 Fuel Feed Pump 4 Electronic Governor Refer to the appropriate Service Manual for disassembling assembling and adjustment procedures of the fuel injection pump Figure 6 2 1 governor and timer for 6LY3 engines NOTICE The fuel injection pump and the rack position sensor amplifier may only be disassembled at an authorized FIE ...

Page 150: ...ne International Fuel Injection Pump Components Figure 6 3 Figure 6 3 8 4 3 2 7 6 1 5 91 5 110 3 8 0 7 79 2 376 2 78 7 No 1cyl No 2cyl No 3cyl No 4cyl No 5cyl No 6cyl 142 10 7 14 200 5 27 32 32 35 32 32 232 26 0 5 59 8 200 5 59 8 0 86 113 47 4 9 2 1 3 5 6 7 8 10 8 4 3 2 7 6 1 5 ST 0005666 ...

Page 151: ...al 6 9 2007 Yanmar Marine International 1 Governor 2 Fuel Inlet M14 x 1 5 3 Oil Inlet M8 4 Rack Position Standard Surface 5 Overflow of Fuel Outlet 6 Rack Cover 7 Timer Device 8 Fuel Feed Pump 9 Camshaft Key Position at FIC No 1 Cylinder 10 Rack Position Sensor Amplifier ...

Page 152: ...Figure 6 4 3 and detects the rack position The governor solenoid is linked to the control rack and actuates it according to the rack position which is calculated by the ECU Electronic Control Unit This governor has a function of iso chronous control Actual engine speed is feedback controlled to the target speed throttle position Engine speed varies directly with throttle position Figure 6 4 Figure...

Page 153: ...as helical spline outside and straight spline inside as illustrated in Figure 6 6 The cylinder Figure 6 6 6 has helical splines inside and oil passages to move the piston The cam drive coupling Figure 6 6 9 has a straight spline outside and drives the pump camshaft Figure 6 5 Figure 6 5 Figure 6 6 Figure 6 6 1 Electromagnetic Valve 2 Helical Spline 3 Piston 4 Straight Spline 5 Cam Tightening Nut 6...

Page 154: ...inlet outlet according to ECU indications When advancing the timer solenoid opens the advance port to the oil inlet side and opens the retard port to the oil outlet side The advance chamber is pressurized with oil and the oil in the retard oil chamber Figure 6 7 5 is pumped out through the engine oil outlet Figure 6 7 9 Then the timer piston moves as a result of oil differential pressure and rotat...

Page 155: ...LY3 Service Manual 6 13 2007 Yanmar Marine International Advanced Position Figure 6 8 Figure 6 8 1 Timer Solenoid 2 Pump Drive Gear 3 Cylinder 4 Piston 5 Damper Shaft 6 Drive Direction 7 Piston Movement 8 Rotating Cam and Piston 1 3 3 4 4 2 6 5 7 8 0005671 ...

Page 156: ...are closed on the compression stroke 2 At 29 BTDC the index marks on the V pulley Figure 6 9 2 and drive shaft housing cover Figure 6 9 1 should align Figure 6 9 Figure 6 9 1 Index Mark Drive Shaft Housing Cover 2 Index Mark V Pulley 3 Remove the fuel injection lines supply lines and cap the ends to keep dirt out 4 Remove the damper Figure 6 10 3 on the fuel injection pump Figure 6 10 Figure 6 10 ...

Page 157: ...k bolt and a collar through the FIC lock hole Figure 6 12 1 of the fuel injection pump gear to lock the camshaft of the fuel injection pump before removing the fuel injection pump gear The camshaft angle of this pump is in the same as factory default NOTICE If the fuel injection pump is removed without fastening an FIC lock bolt the pump camshaft angle may change and the adjustment of the fuel inj...

Page 158: ...Bolts 10 Remove the bolts for the governor bracket Figure 6 15 6 Figure 6 15 Figure 6 15 1 Pump Bracket B 2 Pump Bracket A 3 Drive Shaft Housing 4 Electromagnetic Valve 5 Pump Bottom Bracket 6 Governor Bracket 11 Remove the bolts for pump bracket B Figure 6 15 1 12 Remove the bolts for pump bottom bracket Figure 6 15 5 13 Remove the bolts for the timer housing and remove the fuel injection pump as...

Page 159: ...may lead to a malfunction of the pump Install the brackets following the steps outlined below 1 Insert two spring pins Figure 6 17 1 in the flange of the timer housing of the fuel injection pump Assemble and install the retainer Figure 6 17 27 while adjusting knocking holes Figure 6 16 Figure 6 16 1 Pump Bracket B 2 Pump Bracket A 3 Drive Shaft Housing 4 Pump Bottom Bracket 5 Governor Bracket Figu...

Page 160: ...nd guide bracket Figure 6 19 2 into position Figure 6 19 Figure 6 19 1 Spring Pins 4 0A x 10 2 Guide Bracket 3 Nut M8 5 Install nuts Figure 6 19 3 and torque to the specified value 6 Apply Three Bond 1207C Figure 6 20 1 to the drive shaft housing mating surface of the timer housing Figure 6 20 Figure 6 20 1 Apply Three Bond 1207C Bottom Bracket Bolt Torque Tightening Torque 49 5 N m 5 0 0 5 kgf m ...

Page 161: ... the force of the timer flange Figure 6 22 2 Figure 6 21 Figure 6 21 1 M8 x 25 10T Bolt 2 M8 x 60 Dummy Bolt Figure 6 22 Figure 6 22 1 Piston 2 Timer Flange 8 Ensure the threads are clean and dry Initially tighten the bolts Figure 6 23 1 on the pump bottom bracket to the cylinder block Confirm that there is no gap between the bracket and the cylinder block Figure 6 23 Figure 6 23 1 M8 x 25 Bolt 2 ...

Page 162: ...M8 x 25 10T Bolt 10 Tighten the bolts for the pump bottom bracket Figure 6 25 to the specified torque valve as shown Figure 6 25 Figure 6 25 1 M8 x 25 Bolt 2 M10 x 25 Bolt 11 Remove the dummy bolts Figure 6 26 1 Figure 6 26 Figure 6 26 1 Dummy Bolts Final Torque Timer Housing Bolts 35 3 2 N m 3 6 0 2 kgf m 26 0 1 5 lb ft 0005687 1 Final Torque Pump Bottom Bracket Bolts M8 bolt 25 5 3 N m 2 60 0 31...

Page 163: ... Figure 6 29 Tighten the bolts for the block Figure 6 29 1 and bolts for pump Figure 6 29 2 to initial torque Figure 6 29 Figure 6 29 1 M8 x 40 Bolt 2 M8 x 16 Bolt 15 Tighten the bolts to the final specified torque in the order shown in Figure 6 30 Figure 6 30 Figure 6 30 Initial Torque Pump Bracket Bolts 4 0 1 N m 0 40 0 1 kgf m 2 9 0 737 lb ft Final Torque Pump Bracket Bolts Final Torque 25 5 3 ...

Page 164: ...igure 6 31 Figure 6 31 1 Pump Gear 2 Idler Gear 3 Idler Gear Index Mark B 4 Pump Gear Index Marks 17 Align the FIC lock bolt holes of the damper shaft Figure 6 32 2 with the fuel injection pump gear Figure 6 32 1 Tighten them together while turning the pump gear counterclockwise to take up the gear lash Tighten the bolts to the following specified value Figure 6 32 Figure 6 32 1 Fuel Injection Pum...

Page 165: ... 1 Timer Cover 2 Oil Seal 20 Apply an even bead of Three Bond 1207C sealant Figure 6 35 3 on the mating surface of timer cover Figure 6 35 2 Figure 6 35 Figure 6 35 1 M8 x 85 mm Bolts 2 Timer Cover 3 Three Bond 1207C Sealant 4 M8 x 120 mm Bolts 5 New Oil Seal 6 M8 x 30 mm Bolts 7 M8 x 65 mm Bolt 1 2 0005697 Bolt Torque M8 x 85 mm 20 4 N m 15 5 lb ft M8 x 120 mm 35 5 N m 26 1 lb ft M8 x 30 mm 20 4 ...

Page 166: ...l tank to the fuel pump 6 Defective valve contact of the feed pump 7 Piston spring of the feed pump is broken 8 Inter spindle or tappets of the feed pump are stuck 1 Fill Tank 2 Open 3 Clean and clear 4 Disassemble and clean or replace element 5 Repair 6 Repair or replace 7 Replace 8 Repair or replace No fuel delivered to injection pump 1 Plunger is worn out or stuck 2 Delivery valve is stuck 3 Co...

Page 167: ... fuel injection adjustment is difficult 5 Feed pump can t feed fuel at low speeds 6 Fuel supply is insufficient at low speeds due to clogging of the fuel filter 1 Repair or replace 2 Adjust 3 Check the trouble code 4 Replace 5 Repair or replace 6 Disassemble and clean or replace the element Engine runs at high speeds but cuts out at low speeds 1 The electric control system is defective 2 Control r...

Page 168: ...p which can maintain the DENSO fuel nozzles Fuel Injection Nozzle Functions A double spring type fuel nozzle is used with this engine This allows each nozzle to inject fuel in two steps Fuel from the fuel injection pump passes through the fuel port in the nozzle body holder and enters the nozzle body reservoir Figure 6 36 Figure 6 36 1 Nozzle Body Holder 2 M6 x 1 0 mm 3 M12 x 1 5 mm 4 M15 x 0 5 mm...

Page 169: ...l 6LY3 ETP 6LY3 STP 6LY3 UTP Nozzle ID Mark D DLLA155P913 D DLLA155P954 Spray Angle 155 No of Injection Hole and Diameter 7 Ø0 26 mm 0 27 in 0 010 in Nozzle Opening Pressure No 1 Pressure 24 00 24 98 MPa 245 255 kgf cm2 3480 3611 psi No 2 Pressure 36 96 38 34 MPa 377 391 kgf cm2 5351 5554 psi Nozzle Lift Pre Lift 0 24 0 30 mm 0 009 0 011 in Full Lift 0 33 0 38 0 012 0 014 in Body Mark D 8000 D 809...

Page 170: ...g The fuel feed pump is driven by an eccentric cam on the fuel camshaft When the cam pushes on the piston via the roller guide the fuel in the piston chamber passes through the discharge valve and flows behind the piston The suction valve closes under pressure and prevents the fuel from flowing back to the tank When the cam is lowered the piston is pushed back by the piston spring and the fuel beh...

Page 171: ...ure 6 37 Figure 6 37 1 Cover 2 Priming Pump 3 O Ring 4 Priming Pump Valve Spring 5 Priming Pump Valve 6 Piston 7 Piston Spring 8 O Ring 9 Piston Spring Plug 10 Roller Guide 11 Roller Pin 12 Roller 13 Retaining Ring 14 Discharge Valve 15 Discharge Valve Spring 16 O Ring 17 Plug 18 Inter Spindle 1 2 3 4 5 6 7 8 9 11 12 13 10 17 16 15 14 18 0005700 ...

Page 172: ...nt fuel supply and abnormal wear of the tappets and camshaft Assembling the Fuel Feed Pump 1 Position the discharge valve and spring in the fuel feed pump housing Lubricate and install a new O ring on the discharge valve plug Install the discharge valve plug 2 Lubricate and install a new O ring on the priming pump Install the priming pump 3 Position the piston and piston spring in the fuel feed pu...

Page 173: ...igure 6 39 Figure 6 39 1 From Fuel Tank 2 Fuel Delivery Suction Test for the Priming Pump Loosen the handle of the priming pump and push the handle at 60 100 strokes minute If fuel comes out of the delivery side of the feed pump Figure 6 40 4 after about 30 strokes the priming pump is normal If it takes longer replace the priming pump as a set Figure 6 40 Figure 6 40 1 Valve B 2 Pressure Gauge 3 V...

Page 174: ...pm and read the pressure gauge indicator when Valve B Figure 6 41 1 is closed 2 Tighten Valve A Figure 6 41 1 so the pressure gauge indicator does not move when pressure is applied 3 Replace the piston spring if it is defective Delivery Test 1 Open Valve A Figure 6 42 2 2 Operate the fuel injection pump at the specified 1000 rpm 3 Open Valve B Figure 6 42 1 until the pressure gauge indicator shows...

Page 175: ...fed through the pores in the filter and discharged from the center of the cover Dirt and foreign matter in the fuel are deposited in the filter element Figure 6 43 Figure 6 43 1 Return From Fuel Nozzle 2 Fuel Filter Body 3 Flow From Fuel Feed Pump 4 Return From Fuel Pump 5 Drain Plug 6 Flow to Fuel Pump Figure 6 44 Figure 6 44 1 M14 x 1 5 mm 2 M14 x 1 5 mm 3 M8 x 1 25 mm 2 6 5 3 4 1 0005707 Fuel F...

Page 176: ...oreign matter in the strainer bowl disassemble the strainer and wash with clean fuel to completely remove foreign matter Replace and or clean at scheduled intervals Replace the filter if it is very dirty deformed or damaged Figure 6 45 Figure 6 45 1 Attaching Hardware 2 Fuel Filter Assembly 3 Gasket 4 Cover 5 Filter Case 6 Drain Plug 7 Center Bolt 8 Filter Element 9 Rubber Pad 2 3 4 5 6 7 9 8 1 00...

Page 177: ... the 6LY3 series engines In order to function the Engine Control Unit ECU the electronic governor and electro hydraulic timer are interconnected to the fuel injection pump The ECU controls the fuel injection quantity and injection timing electronically This engine is also equipped with an engine control unit an engine interface module and other electronic control equipment ...

Page 178: ...6 Rocker switch panel Throttle signal Neutral signal Emergency stop Switch Start Switch Ignition Switch Backup throttle sensor CAN ECU Intake air pressure sensor Oil pressure sensor Water temperature sensor Oil temperature sensor Crank angle sensor Main relay Air heater relay Rack actuator relay Timer solenoid advance Timer solenoid retard Electronic governor Rack position amplifier Rack position ...

Page 179: ...rs are installed for the purpose of monitoring and warning the vessel operators Figure 6 47 Figure 6 47 Injection pump Crank speed sensor On flywheel housing Oil temperature sensor On oil cooler Electronic governor Rack position sensor On governor Pump speed sensor On governor Fuel temperature sensor On injection pump Timer solenoid On hydraulic timer Boost pressure sensor On intake manifold Water...

Page 180: ...uantity control diagram by ECU is shown in Figure 6 48 Figure 6 48 Figure 6 48 1 4 2 4 3 4 4 4 Boost pressure Fuel oil temperature Coolant temperature Throttle position Crank speed Rack position Input Output Target speed calculation depend on throttle position Target governor position calculation basically depend on target speed and actual speed Starting only Engine speed target cal Load Speed Idl...

Page 181: ... torsion angle between the pump camshaft and pump drive gear The ECU injection timing control diagram is shown in Figure 6 49 Figure 6 49 Figure 6 49 Input Output Coolant temperature Rack position Crank speed Cam speed Timer solenoid Advance Timer solenoid Retard Timer phase target cal Timer phase control cal Engine load cal Timer phase cal Rack position Speed Rmax Ridle Engine load 100 0005713 ...

Page 182: ...detected by two pulsar gears Figure 6 50 and is calculated by the ECU from the deviation of two pulses The pulsar gear of crankshaft is located on the flywheel Figure 6 50 Figure 6 50 Timer phase detection Top pulse Top pulse Top pulse Crank pulse Cam pulse 360 Crank angle 0 360 12 pulse 12 1 pulse Cam gear Crank gear Pulsar gear 0005714 ...

Page 183: ...jection pump when it is necessary ECU Control Data Management In Factory The flow of ECU control data management in the factory is shown in Figure 6 51 Control program data map and data are assigned to a part number for each engine model Engine production data and adjustment data are specific for each engine and injection pump The ECU control data for each engine is stored in the factory server af...

Page 184: ...ustment Data by using a YDT The rewriting of the ECU control data is performed by Yanmar authorized personnel when replacement of an ECU or its components is necessary NOTICE 1 Data rewriting is permitted only by an authorized Yanmar technician 2 Data rewriting is performed by using a YDT which was originally developed by Yanmar YDT consists of PC software engine interface and connections 3 YDT re...

Page 185: ...tory the ECU control data is selected according to the engine identification information such as the engine serial number and pump serial number Then an ECU is provided directly by the factory The data is stored in the production system network Figure 6 53 Figure 6 53 ORDER of ECU for replacement DATA SERVER in factory PRODUCTION SYSTEM ENGINE MODEL SERIAL NUMBER PROGRAM MAP PRODUCTION DATA ENG PU...

Page 186: ...FUEL SYSTEM Electronic Control System 6 44 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 187: ... Coolant Pump 7 11 Inspecting the Coolant Pump 7 11 Heat Exchanger Components and Functions 7 13 Heat Exchanger Components 7 13 Disassembling the Heat Exchanger 7 13 Inspecting the Heat Exchanger 7 14 Pressure Cap Operation 7 14 Inspecting the Pressure Cap 7 15 Coolant Recovery Tank Components and Functions 7 16 Installing the Coolant Recovery Tank 7 16 Coolant Recovery Tank Precautions 7 16 Therm...

Page 188: ...07 Yanmar Marine International Bilge Pump Characteristics 7 21 Bilge Pump Insulation 7 21 Bilge Pump Durability 7 21 Bilge Pump Vibration Proof 7 21 Bilge Pump Precautions 7 21 Installing the Bilge Pump 7 21 Troubleshooting the Bilge Pump 7 23 ...

Page 189: ...age has CAUTION level hazards The safety message describes a hazardous situation which if not avoided could result in minor or moderate injury Coolant Hazard Wear eye protection and rubber gloves when handling Long Life Coolant LLC If contact with the eyes or skin should occur flush eyes and wash immediately with clean water INTRODUCTION This section of the Service Manual describes the procedures ...

Page 190: ... discharged from the boat with the exhaust gas Coolant is pumped by the coolant pump from the coolant tank to the cylinder jacket to cool the cylinders turbocharger and then the cylinder head The coolant pump body also serves as a discharge passageway line at the cylinder head outlet and is fitted with a thermostat The thermostat is closed when the coolant temperature is low immediately after the ...

Page 191: ...l Coolant System Components Figure 7 1 Figure 7 1 1 Fuel Injection Pump 2 Oil Cooler 3 Bypass Oil Filter 4 Full Flow Oil Filter 5 Intercooler 6 Marine Gear Oil Cooler 7 Mixing Elbow 8 Coolant Outlet 9 Heat Exchanger 10 Seawater Inlet 11 Seawater Pump 12 Thermostat 13 Coolant Pump 0006200 9 8 7 6 5 4 3 2 1 10 11 12 13 ...

Page 192: ...11 Seawater Pump Body 12 Wear Plate 13 End Cover 14 Seawater Pump Outlet 2 Remove the seawater pump assembly from the drive shaft housing Figure 7 3 9 3 Remove the seawater pump end cover Figure 7 3 13 Seawater Pump Performance Specifications Flow Minimum 215 L min 57 gal at In 0 4 bar 6 psi Out 1 2 bar 17 5 psi 2933 rpm after 100 hours of duty Self Priming Ability Maximum 10 seconds at suction he...

Page 193: ...cal seal if necessary Inspecting the Seawater Pump Rubber Impeller If there is damage or wear on the impeller replace it Wear Plate Replace the wear plate if the side surface is worn or deformed Pump Housing Replace the pump housing if there is excessive wear on the inner surface of the housing or on the sliding surface of the impeller Mechanical Seal Replace the mechanical seal if there is water ...

Page 194: ...e shaft with grease before installing 4 Install the O ring 5 Install the pump drive gear and retighten the pump drive gear nut to the specified torque 6 After inserting the mechanical seal install the wear plate and impeller 7 Coat the inside of pump body impeller housing with grease 8 Insert the impeller Figure 7 6 2 into the pump body See Figure 7 6 1 for impeller rotation Impeller threads are t...

Page 195: ...y two V belts from the crankshaft Figure 7 7 Figure 7 7 1 Mechanical Seal 2 Impeller 3 Seal 4 Cover 5 Casing 6 Shaft Bearing 7 Pulley Seat The bearing unit assembled in the pump shaft uses grease lubricated ball bearings and cannot be disassembled The totally enclosed mechanical seal spring presses the impeller seal installed on the impeller side away from the pump body side This prevents coolant ...

Page 196: ... 10 6LY3 Service Manual 2007 Yanmar Marine International Coolant System Components Figure 7 8 Figure 7 8 1 Thermostat 2 Seal 3 Hose Elbow 4 V Belts 5 V Pulley 6 Coolant Pump Assembly 7 Gasket 8 Flange 9 O Ring 10 Cylinder Head 0006207 1 2 3 4 5 6 7 8 9 10 ...

Page 197: ...it Inspection Rotate the impeller If the rotation is not smooth or an abnormal noise is heard or felt replace the pump as an assembly Impeller Inspection Check the impeller blades Replace if damaged corroded or if the impeller blade is excessively worn due to contact with the pump body Coolant and Bypass Lines Check the holes in the coolant and bypass lines clean out any dirt or other foreign matt...

Page 198: ...en the two Figure 7 9 Figure 7 9 1 Thickness Gauge 2 Place a straightedge Figure 7 10 1 against the end of the pump body and insert a thickness gauge Figure 7 10 2 between the impeller and the plate pump body bracket to measure the clearance between the two Figure 7 10 Figure 7 10 1 Straight Edge 2 Thickness Gauge 0006208 1 0006209 2 1 Coolant Pump Clearances Standard Limit Clearance Between the I...

Page 199: ... Cap The filler cap Figure 7 11 3 on top of the coolant tank has a pressure valve which lets off steam through the overflow pipe when pressure in the coolant system exceeds the specified value It also takes in air from the overflow pipe when pressure in the coolant system drops below the normal value Figure 7 11 Figure 7 11 1 Aft Cover 2 O Ring 3 Filler Cap 4 Seal 5 Coolant Tube Core 6 Gasket 7 Fo...

Page 200: ...er and coolant inlets and outlets retighten any joints as necessary and clean the insides of the hoses and lines Heat Exchanger Body Leakage Test Perform a leakage test on the heat exchanger Fit rubber covers on the inlets and outlets of the heat exchanger Submerge the heat exchanger in water Pressurize the tank to the listed pressure and check for leaks Figure 7 13 Figure 7 13 1 Filler Cap 2 Air ...

Page 201: ...nched on the top of the cap for 6LY3 as shown in Figure 7 16 Figure 7 16 Figure 7 16 1 Pressure Valve Identification Inspecting the Pressure Cap WARNING NEVER open the pressure cap while the engine is running or right after shutting down because high temperature steam will be blown out Remove the cap only after the coolant has had a chance to cool down 1 Remove scale and rust check the seat and se...

Page 202: ...p does not need to be removed Figure 7 18 Figure 7 18 1 Filler Cap 2 Coolant Tank 3 Subtank Installing the Coolant Recovery Tank 1 The coolant recovery tank is installed at approximately the same height as the pressure cap on the coolant tank allowable difference in height 300 mm 11 8 in or less 2 The overflow pipe should be less than 1000 mm 39 4 in long and installed so that it does not sag or b...

Page 203: ...as the thermostat valve opens and is completely closed when the coolant temperature reaches 81 5 C 179 F The valve lifts 4 mm 0 16 in sending all of the coolant to the heat exchanger Figure 7 19 Figure 7 19 The thermostat used in this engine is a wax pellet type with a solid wax pellet located in a small chamber When the coolant temperature rises the wax melts and increases in volume This expansio...

Page 204: ...n an electric stove The thermostat is functioning normally if it starts to open between 69 and 73 C 156 and 163 F and opens to 10 mm 0 4 in or more at 85 C 185 F Replace the thermostat if it is not functioning normally Figure 7 21 Figure 7 21 1 Thermometer 2 Thermostat 2 The thermostat should be inspected every 500 hours of operation It should be inspected sooner if the engine temperature rises ab...

Page 205: ...stalled to prevent debris from entering the system Seacock Precautions Always close the seacock after each day of use and confirm that it is open before the beginning of the next day of operation If the seacock is left open seawater will flow in reverse and the vessel will sink if trouble occurs with the water pump If the engine is operated with the seacock closed coolant will not be able to get i...

Page 206: ...1 Motor Assembly 2 Controller 3 White Connector 4 Green Connector 5 Blue Connector 6 Red Connector 7 Red Cable 8 Battery 9 White Cable 10 Inlet 11 Strainer 12 Outlet Bilge Pump and Strainer Components Specifications Name Bilge Pump Time 10 min Rotation Direction Right viewed from the impeller side Negative Pressure Detector Diaphragm type Temperature 30 C to 80 C 22 F to 176 F 0006220 1 2 3 6 5 4 ...

Page 207: ...ng water correctly Bilge water that is left in the hoses pickup strainers and pumps will freeze in cold temperatures Take care to ensure that all residual water is completely discharged from the bilge pump system in temperatures below 0 C 32 F If necessary use a steaming towel to thaw frozen lines and components The pump will require an additional 5 to 10 seconds to operate in freezing temperature...

Page 208: ...lge 3 Turn the pump switch to ON Verify that the water is drawn in and discharged properly The pump will stop automatically when there is no water left 4 If the pump cavitates for more than 10 seconds lift the strainer above the water level and stop the pump Prime the pump before running it again Installing the Strainer After testing the bilge pump install the strainer in place with bolts Avoid da...

Page 209: ...on the pump so that it is closer to the surface of the water The pump is too high Lower the pump Position the pump so that it is 50 70 cm 20 28 in above the bottom of the boat The pump intake is weak If the intake is still faulty after priming consult your local dealer Pump turns but the amount of discharge is low Clogged strainer Clean the strainer The hose is broken or damaged Check for damage a...

Page 210: ...COOLANT SYSTEM Bilge Pump and Strainer Components and Functions Optional 7 24 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 211: ...nents 8 6 Removing the Oil Pump 8 7 Inspecting the Oil Pump 8 7 Installing the Oil Pump 8 7 Oil Pressure Control Valve Components and Functions 8 8 Replacing the Oil Pressure Control Valve 8 8 Oil Filter Components and Functions 8 9 Replacing the Oil Filter 8 9 Oil Cooler Components and Functions 8 10 Inspecting the Oil Cooler 8 10 Rotary Waste Oil Pump Components and Functions Optional 8 10 Rotar...

Page 212: ...LUBRICATION 8 2 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 213: ... internal engine components to seize and or shorten engine life NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil 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 Consult the local authorit...

Page 214: ...e crankshaft journals Figure 8 1 9 and lubricates the crank pins from the crankshaft journals Oil for the fuel injection pump Figure 8 1 1 is sent by lines from the main gallery to the fuel injection pump Figure 8 1 1 Oil for the turbocharger Figure 8 1 6 is sent by lines from the oil filter Figure 8 1 5 to the turbocharger Figure 8 1 6 The oil pressure throughout the system is regulated by the sa...

Page 215: ...2 6 is located on the cylinder block behind the oil cooler Figure 8 2 Figure 8 2 1 Cylinder Block 2 Idler Gear 3 Shims 4 Oil Pump 5 Intake Filter 6 Oil Pressure Regulating Valve Oil Pump Specifications 0006222 1 6 5 2 4 3 Pump Test Performance Theoretical Delivery 32 8 cc 1 1 oz per revolution Delivery 94 5 L 25 gal or more Delivery Pressure Safety Valve 0 8 MPa 116 psi Pump Speed 3200 rpm Engine ...

Page 216: ...ernational Oil Pump Components Figure 8 3 Figure 8 3 1 Direction of Rotation 2 Cover 3 Shaft 4 Gear 5 Case 6 Drive Gear 7 Shaft 8 Gear 9 Washer 10 Safety Valve Case 11 Seat 12 Spring Pin 13 Spring 14 Ball 200 100 35 35 43 758 33 36 5 55 76 76 879 52 103 0006223 1 2 3 4 5 6 7 8 14 13 12 11 10 9 ...

Page 217: ... oil pump gear to pump cover clearance with straight edge and gauge Figure 8 5 Figure 8 5 Figure 8 5 1 Straight Edge 2 Feeler Gauge NOTICE 1 The oil pump should be disassembled only when oil pressure is insufficient even after adjusting the oil pressure regulator valve 2 When assembling make sure the oil pump gears rotate smoothly Installing the Oil Pump 1 Install the oil pump on the main bearing ...

Page 218: ...pressure control valve piston opens a pressure outlet and allows excess oil to drain back to the oil pan Replacing the Oil Pressure Control Valve The control valve was set at the factory it should not require adjustment If the oil pressure control valve is disassembled due to spring trouble install a pressure gauge on the oil pressure sending unit mounting washer Adjust the pressure with adjustmen...

Page 219: ... 1 Cover Seal 2 Cover Assembly 3 Filter Element 4 Filter Case 5 Set Spring 6 Caution Label 7 Element Seal Figure 8 8 Figure 8 8 1 Full Flow Oil Filter 2 Filter Bracket 3 Bypass Oil Filter Replacing the Oil Filter See Removing the Oil Filter and Oil Cooler on page 5 20 and Installing the Engine Oil Filters on page 5 71 0006227 5 4 3 2 1 6 7 Specifications Pressure Loss Full flow Bypass 0 03 MPa 4 4...

Page 220: ...buildup 2 If the rubber hose connection or welds are corroded repair or replace the cooler 3 Apply the following water pressures to the seawater and oil lines to check for any leaks Repair or replace the cooler if there are any leaks ROTARY WASTE OIL PUMP COMPONENTS AND FUNCTIONS OPTIONAL A rotary waste oil pump Figure 8 10 used to pump out waste oil during oil changing is available as an option T...

Page 221: ... drop in discharge volume Replace damaged components if necessary 2 Replace the oil seal Figure 8 11 3 if there is excessive oil leakage from the handle shaft Figure 8 11 4 3 Replace the impeller if there is an excessive gap between the impeller and the covers on both sides of the casing This will cause a drop in discharge volume 4 The hose coupling threads are coated with adhesive when installed ...

Page 222: ...LUBRICATION Rotary Waste Oil Pump Components and Functions Optional 8 12 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 223: ...tions 9 9 Inspection Intervals 9 9 Checking the Rotor Rotation 9 9 Checking the Rotor Axial Play 9 10 Checking the Rotor Radial Play 9 11 Disassembling the Turbocharger 9 12 Special Tools 9 12 Inspecting the Turbocharger Before Disassembling 9 14 Disassembling the Turbocharger 9 14 Inspecting the Turbocharger 9 15 Inspecting Major Items 9 15 Cleaning the Turbocharger 9 15 Inspecting the Turbocharg...

Page 224: ...ng the Compressor Housing 9 21 Connecting the Boost Hose 9 21 Post Assembly Inspection 9 21 Handling the Turbocharger 9 22 Precautions for Installing the Turbocharger to the Engine 9 22 Troubleshooting the Turbocharger 9 23 Black Smoke 9 23 White Smoke 9 24 Excessive Oil Consumption 9 24 Reduced Engine Power 9 24 Poor Follow Up of the Turbocharger 9 24 Unusual Sound or Vibration 9 25 ...

Page 225: ...3 2007 Yanmar Marine International SAFETY PRECAUTIONS Before servicing the engine turbocharger review the Safety Section on page 2 1 INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 6LY3 marine engine turbocharger ...

Page 226: ...e Screw 6 E Circlip 7 Turbine Pressure Plate 8 Turbine Hexagon Bolt 9 Turbine Rotor Shaft 10 Turbine Seal Ring 11 Insulation Plate 12 Bearing Housing 13 Floating Bearing B 14 Retaining Rings 15 Floating Bearing 16 Thrust Bushing 17 Thrust Bearing 18 TORX T M3 Machine Screw 19 Oil Thrower 20 Large Seal Ring 21 Small Seal Ring 22 Seal Plate 23 TORX T M4 Machine Screw 24 Compressor Impeller 25 Turbin...

Page 227: ...additional torque through the turbine shaft to the compressor impeller The impeller compresses intake air and delivers it to the intake manifold Bearings The thrust bearing axial bearing prevents the turbine shaft from shifting due to the constant thrust loads of the turbine The radial bearings use double oil films on their inside and outside surfaces that flow in the direction of bearing rotation...

Page 228: ...CHARGER Maintenance Standards 9 6 6LY3 Service Manual 2007 Yanmar Marine International MAINTENANCE STANDARDS Standard Limits Figure 9 2 Figure 9 2 F B E A C H1 H2 G2 G1 K J F B E A C H1 H2 G2 G1 K J 0005895 ...

Page 229: ...in 16 980 mm 0 6685 in 17 110 mm 0 6736 in See Floating Bearings on page 9 17 Thrust Bearings J Thrust Bearing Width K Thrust Bushing Groove to Groove Dimension 4 480 mm 0 1764 in 4 680 mm 0 1845 in See Thrust Bearing and Oil Thrower on page 9 16 Seal Ring Insertion Parts F Turbine Side Bearing Housing H1 Compressor Side Seal Plate Large H2 Compressor Side Seal Plate Small 18 550 mm 0 7303 in 16 0...

Page 230: ...b ft Coat with seizure preventative 2 Seal Plate TORX T M4 Machine Screw 3 7 0 3 N m 2 7 0 2 lb ft Apply Loctite 242 3 Compressor Housing Hex Bolts M8 23 1 N m 16 9 0 7 lb ft NA 4 Sealing Surface of Compressor Housing and Seal Plate NA Fluid sealant to be applied here 5 Compressor Impeller Shaft End Nut M8 Left Hand Thread 7 8 0 5 N m 5 7 0 3 lb ft NA 6 Thrust Bearing TORX T M3 Machine Screw 1 27 ...

Page 231: ... for any abnormal sounds during operation Use a listening rod to help diagnose any potential problems Position the tip of the bar firmly on the turbocharger case and gradually increase engine rpm If high pitched sounds are generated at intervals of 2 to 3 seconds some type of abnormal operation is present Any such indication is cause for turbocharger inspection overhaul or replacement Purpose of U...

Page 232: ...ial indicator as shown in Figure 9 4 4 Move the turbine impeller back and forth in an axial direction Figure 9 4 6 and measure travel on the dial indicator 5 Compare readings with the maintenance standard limits that follow Figure 9 4 Figure 9 4 1 Turbine Housing 2 Oil Outlet 3 Magnetic Base 4 Dial Indicator 5 Oil Inlet 6 Move the turbine rotor shaft in an axial direction Rotor Axial Play 0 06 0 0...

Page 233: ...rasp both the turbine and impeller and move them back and forth evenly in a radial direction Figure 9 5 3 3 Measure the travel with the dial indicator 4 Compare readings with the maintenance standard limits that follow Figure 9 5 Figure 9 5 1 Dial Indicator 2 Magnetic Base 3 Move the turbine rotor shaft back and forth evenly in a radial direction 4 Oil Inlet Rotor Radial Play 0 11 0 18 mm 0 004 0 ...

Page 234: ...g bearing retaining ring Pliers For installing and removing the seal ring Torque Screwdriver for TORX bolt Universal type 5 50 kg cm For installing the seal plate 3 7 0 3 N m 2 6 lb in for M4 For installing the thrust bearing 1 27 1 N m 11 2 lb in for M3 Available in the market Torque Wrench Single purpose type For installing the turbine housing 28 1 N m 20 6 lb in for M8 For installing the compre...

Page 235: ...Box Wrench For installing the turbine shaft 14 mm x 12 spline Measuring Probe Measurement of play in axial and radial directions 1 Put on the Rolette 2 Set it to the Dial Gauge A B C D E F G H I J 8 80 11 24 M26 P0 45 1 15 5 L 10 L Ø5 Name of Tool Purpose of Use Remarks 0006243 A B C D I J E G F H 0006244 1 2 ...

Page 236: ...e housing Removing the Turbine Rotor Shaft 1 Press down lightly with your hand on the turbine housing and pull out the turbine rotor shaft NOTICE If removing the shaft becomes difficult tap it lightly with a wooden hammer on the compressor side shaft end 2 Remove the insulation plate Removing the Seal Plate 1 Loosen the seal plate retaining M4 TORX T across head machine bolt with a TORX screwdrive...

Page 237: ...g insertion grooves Section Tools and Detergent Cleaning Procedure Turbine Rotor Shaft Turbine rotor shaft tools 1 Washing bucket 500 x 500 2 Heat source steam or gas burner 3 Brush Detergent Carbon Solvent 1 Immerse the turbine shaft in the washing bucket and heat the solution 2 NEVER beat the turbine rotor to remove carbon deposits 3 Immerse the parts until dirt deposits become soft by penetrati...

Page 238: ...if any damage is found 2 Measure the outer diameter of the turbine rotor shaft bearing Figure 9 6 1 Figure 9 6 Figure 9 6 1 Turbine Shaft Journal Outside Diameter 2 Seal Ring Groove Width 3 V Block 3 Measure the seal ring groove width and the turbine rotor shaft for runout If it exceeds 0 011 mm 0 0004 in replace the rotor shaft Figure 9 6 2 NOTICE If any value is beyond the specified limits repla...

Page 239: ...rings 1 Inspect the floating bearing for any abnormal wear patterns scratches or discoloration Replace the floating bearings if any discrepancies are found 2 Measure the inside Figure 9 9 1 and outside Figure 9 9 2 diameters If worn beyond limits replace the bearings with new ones Figure 9 9 Figure 9 9 1 Inside Diameter 2 Floating Bearing 3 Outside Diameter Oil Thrower Seal Ring Grooves Groove G1 ...

Page 240: ...r of the floating bearing Figure 9 10 3 and the turbine side seal ring hole Figure 9 10 6 If they are found greater than the specified limits replace the bearing housing and or the floating bearing Seal Plate 1 Check the seal plate Figure 9 11 1 for any evidence of interference nicks or cracks If any damage is found replace the seal plate Figure 9 11 Figure 9 11 1 Seal Plate 2 Seal Ring Hole 3 Sea...

Page 241: ...nd other associated hardware Replace any damaged components ASSEMBLING THE TURBOCHARGER NOTICE Always replace M3 and M4 TORX T machine bolts when assembling a turbocharger unit NOTICE Always replace the following parts when assembling an RHC7W turbocharger unit Four compressor side seal rings small Five compressor side seal rings large Four M3 TORX T Machine Screws 3 ea Four M4 TORX T Machine Scre...

Page 242: ... Face the slot of the seal ring toward the oil inlet and align the seal ring with the turbine rotor shaft Installing the Thrust Bearing 1 Install the thrust bearing on the turbine rotor shaft 2 Apply engine oil to the thrust bearing and place the thrust bearing in the bearing housing 3 Use M3 TORX T machine bolts and tighten to the specified torque value Installing the Seal Plate 1 Install the sea...

Page 243: ... join the compressor housing to the bearing housing 3 Make sure the oil inlet oil outlet and air outlet are in their correct positions 4 Attach the compressor pressure plates and tighten the M8 hexagon bolts to the specified torque Connecting the Boost Hose 1 Place the clips to the center of the boost hose 2 Install the boost hose from the compressor housing to the wastegate actuator Figure 9 1 3 ...

Page 244: ...oil inlet and outlet lines 3 Check the oil fittings to ensure tight and secure connections Intake System 1 Make sure there is no rubbish or foreign matter in the air intake components 2 Install the turbocharger securely and avoid any leaks in the air induction system Exhaust System 1 Make sure there is no rubbish or foreign matter in the exhaust manifold or any other component that feeds into the ...

Page 245: ...r Bearing Seizure Insufficient oil feed or clogging of pipe Oil temperature is too high Imbalance of the rotating part Insufficient warm up operation or abrupt stopping of the operation under load No load operation Disassemble and repair the turbocharger Inspect the engine oil system Change the oil Replace or repair the rotating part Observe the operating precautions described in the Operator s Ma...

Page 246: ...ormally or is broken because of excessive bearing abrasion Disassemble and repair the turbocharger Possible Cause Correction Gas leak in the exhaust gas system Air leaks at the discharge side of the compressor Clogging of the air cleaner element Turbocharger is contaminated or damaged Disassemble and repair exhaust system Repair leak Clean or replace the element Disassemble and repair or replace t...

Page 247: ...ging Rotating part is obstructed Interference of rotating part s Disassemble and clean the turbocharger Disassemble repair or replace the turbocharger Possible Cause Correction Connection between the turbocharger and the suction or exhaust pipe or oil pipe is loosened Turbine rotor shaft or compressor impeller is broken because of bearing failure rotating part interference or entry of foreign matt...

Page 248: ...TURBOCHARGER Troubleshooting the Turbocharger 9 26 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 249: ...l 6LY3 Service Manual Section 10 STARTER Page Safety Precautions 10 3 Introduction 10 3 Starter Components and Functions 10 4 Starter Specifications 10 4 Starter Characteristics 10 5 Starter Components 10 6 Starter Operation 10 8 Starter Wiring Diagram 10 8 ...

Page 250: ...STARTER 10 2 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 251: ...battery switch if equipped or disconnect the negative battery cable before servicing the equipment ALWAYS check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Indicates a situation which can cause damage to the machine personal property the environment or cause the equipment to operate improperly NEVER engage the star...

Page 252: ... friction loss and starts the engine Starter Specifications YANMAR Part No 129940 77010 HITACHI Model No S14 102 Nominal Power kW 3 0 Nominal Voltage V 12 Rating seconds 30 Direction of Rotation Looking from the pinion side Clockwise Number of Pinion Teeth 9 Mass kg 6 5 14 3 lb No Load Terminal Voltage V 12 Electric Current A 160 maximum Revolutions rpm 3600 minimum Load Terminal Voltage V 10 85 E...

Page 253: ...ponents and Functions 12 05 6LY3 Service Manual 10 5 2007 Yanmar Marine International Starter Characteristics Figure 10 1 Figure 10 1 1 Output kW 2 Torque N m 3 Speed rpm 4 Voltage V 5 Current A 0006270 rpm N m 1 2 3 4 5 ...

Page 254: ...STARTER Starter Components and Functions 10 6 6LY3 Service Manual 2007 Yanmar Marine International Starter Components Figure 10 2 Figure 10 2 0006603 1 5 6 7 8 4 3 11 9 10 19 18 16 17 15 14 13 12 2 ...

Page 255: ...al 1 Flywheel Housing 2 Starting Motor Assembly 3 Bearing Retainer 4 Drive Shaft Housing 5 Shift Lever 6 Magnetic Switch Solenoid 7 Pinion Stop 8 Clutch 9 O Ring 10 Brush Assembly 11 Pinion 12 Armature 13 Field Coil 14 Yoke 15 Brush Assembly 16 Brush Holder 17 Brush Spring 18 Rear Cover 19 Through Bolt ...

Page 256: ... core of the switch is energized This extends the contact end of the solenoid to close the circuit between the battery and the starter motor As the core extends to close electrical contacts on one end the other end of the solenoid core moves a lever that pushes the pinion gear against spring pressure into engagement with the teeth of the flywheel ring gear 2 With battery power being supplied to th...

Page 257: ...nual Section 11 ALTERNATOR Page Safety Precautions 11 3 Introduction 11 4 Alternator Components and Functions 12V 80A 11 5 Alternator Specifications 11 5 Alternator Components 11 6 Alternator Wiring Diagram 11 8 Alternator Characteristics 11 9 Inspecting the Alternator 11 9 ...

Page 258: ...ALTERNATOR 11 2 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 259: ...brasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Indicates a situation which can cause damage to the machine personal property and or the environment or cause the equipment to operate improperly NEVER turn the battery switch off or disconnect the battery leads from the battery while the engine is operating Damage to the alternator will result NEVER reverse...

Page 260: ...RNATOR Introduction 11 4 6LY3 Service Manual 2007 Yanmar Marine International INTRODUCTION This section of the Service Manual describes the procedures necessary to service the 6LY3 marine engine alternator ...

Page 261: ...ulator that is designed to deliver a constant voltage throughout a wide range of engine speeds and uses diodes to convert AC to DC Figure 11 1 Figure 11 1 1 Alternator Alternator Specifications 1 0006272 Part No 119578 77210 Alternator Model L X4447 HITACHI Battery Voltage 12V Nominal Output 12V 80A Polarity Negative Ground Direction of Rotation viewed from pulley end Clockwise Weight 5 8 kg 12 7 ...

Page 262: ...ne International Alternator Components Figure 11 2 Figure 11 2 1 Pulley 2 Fan 3 Front Cover 4 Bearing 5 Bearing Retainer 6 Rotor 7 Bearing 8 Stator 9 Through Bolts 10 Bracket Bolts 11 Condenser 12 Rear Cover 13 Regulator 14 Brush 15 Condenser 16 Diode 1 2 3 4 5 6 7 8 12 11 10 9 13 16 15 14 0006273 ...

Page 263: ...mar Marine International Figure 11 3 Figure 11 3 1 Pulley Nut 2 Pulley 3 Ball Bearing 4 Bearing Retainer 5 Front Cover Assembly 6 Stator 7 Rotor 8 IC Regulator 9 Ball Bearing 10 Rear Cover 11 Insulating Bushing 12 Bolt 13 Spacer 14 Through Bolt 85 90 170 1 2 5 3 4 6 7 12 13 14 8 9 10 11 0006274 ...

Page 264: ...ring Diagram Figure 11 4 Figure 11 4 NOTICE Make all connections carefully Never attempt to remove connections while the alternator is functioning Turn battery switch off when engine is stopped Rotor Coil Stator Coil Alternator Diode Sub Coil Condenser IC Regulator BAT Battery Battery Switch Key Switch P R L R L F E E 0006275 ...

Page 265: ...he Alternator 1 Inspect both belts for any cracks stickiness or visual signs of wear 2 Check that there is clearance Figure 11 6 1 between the bottom of the belts and the bottom of the pulley grooves 3 Check the belt tension 4 Make sure all of the connections and terminals on the alternator are tight 5 Verify that all wires terminate properly in their connectors 6 Rotate the alternator and listen ...

Page 266: ...ALTERNATOR Alternator Components and Functions 12V 80A 11 10 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 267: ...ging the Battery 12 5 Precautions for Battery Storage 12 7 Wiring Diagram 12 8 ECU Connector Pin Configuration 12 9 Sensor Locations 12 10 Sensors for Oil Pressure and Boost Pressure 12 12 Sensors for Water Oil and Fuel Temperatures 12 12 Air Heater Components and Functions 12 13 Air Heater Operation 12 13 Fuse Relay and Harness Components 12 16 Fuse Chart 12 16 Digital Display 12 21 Rocker Switch...

Page 268: ...ELECTRICAL AND ECU 12 2 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 269: ...ive terminals Figure 12 1 1 Figure 12 1 Figure 12 1 1 Terminal 2 Filler Cap 3 Cover 4 Negative Plate 5 Separator Plate 6 Glass Mat 7 Positive Plate 8 Battery Case Power is removed from the battery by connecting a load across these two terminals Figure 12 1 1 When the battery is discharging an electric current flows from the positive plates to the negative plates When the battery is being charged e...

Page 270: ...ns that are found Clean corroded terminals with a wire brush before reconnecting the battery cable Checking the Electrolyte Level Check the electrolyte level every 7 to 10 days The electrolyte must always be 10 to 20 mm 0 4 to 0 8 in over the top of the plates Figure 12 4 Figure 12 4 NOTICE 1 The LEVEL line on a transparent plastic battery case indicates the height of the electrolyte 2 Always use ...

Page 271: ...y Make sure no water gets into the battery 2 If the terminals or other metal parts are corroded due to exposure to electrolyte leakage wash off all of the acid 3 Check the vent holes of the caps and clean if clogged 4 After washing the battery dry it with compressed air connect the battery cable and coat the terminals with the grease NOTICE NEVER coat the terminals before connecting the cables the...

Page 272: ...dicated on the outside of the battery Figure 12 7 2 5 Periodically measure the specific gravity during charging to make sure the specific gravity remains at a high fixed value Also check whether gas is being generated Charging Precautions 1 Remove the battery caps to vent the gas during charging 2 The electrolyte temperature should not exceed 45 C 113 F during charging Figure 12 8 Figure 12 8 3 Si...

Page 273: ...ging with the engine alternator is insufficient because of frequent starts and stops the battery will rapidly lose power Charge the battery as soon as possible when it is used under these conditions An easy to use battery charger is available from Yanmar Take proper care of the battery by using a battery charger Figure 12 10 1 and hydrometer Figure 12 10 Figure 12 10 1 Battery Charger When the spe...

Page 274: ...ELECTRICAL AND ECU Wiring Diagram 12 8 6LY3 Service Manual 2007 Yanmar Marine International WIRING DIAGRAM Figure 12 11 Figure 12 11 ...

Page 275: ...lenoid 3 Advance Timer Solenoid 4 Air Heater Relay 1 5 Air Heater Relay 2 6 Crank Speed Sensor Pulse 7 Cam Speed Sensor Pulse 8 Starter ON 9 Sub Throttle Switch 10 2nd Station Key 11 ECU Power GND 12 ECU Main Relay 13 14 Actuator Relay 15 12V DC 16 Crank Speed Sensor Pulse 17 Cam Speed Sensor Pulse 18 Neutral Switch 19 1st Station Key 20 Emergency Stop 21 Starter Check 22 Sub Throttle Indicator 23...

Page 276: ...l unit ECU and used for engine control and system monitoring Sensor Locations Figure 12 13 Figure 12 13 1 Boost air pressure sensor installed on the intake manifold with sealant tape Torque 9 8 1 N m 7 2 0 7 lb ft 2 Oil pressure sensor installed on the oil filter bracket with sealant tape Torque 9 8 1 N m 7 2 0 7 lb ft 3 Coolant temperature sensor installed on the heat exchanger with sealant tape ...

Page 277: ...mperature sensor installed on the oil cooler with sealant tape Torque 19 6 3 N m 14 4 2 2 lb ft 2 Fuel temperature sensor installed on the fuel injection pump Torque 19 6 3 N m 14 4 2 2 lb ft 3 Fuel injection pump rpm sensor installed on the fuel injection pump 4 Crankshaft rpm sensor installed on the flywheel housing 1 2 3 4 0006279 ...

Page 278: ...d on the exhaust manifold near the thermostat A water temperature switch is not used Data from the water temperature sensor is used by the ECU for alarm indications instead of a water temperature switch The oil temperature sensor is located on top of the oil cooler The fuel temperature sensor is located on the side of the fuel injection pump Figure 12 17 Figure 12 17 Figure 12 17 Oil Pressure Sens...

Page 279: ...CU 2 Battery 3 Air Heater A 4 Air Heater B Figure 12 19 Figure 12 19 2 1 3 4 0006285 Key On Air Heater B Engine Speed Time Pre Heat Air Heater is on when the coolant temperature is less than 10 C 50 F maximum 30 seconds while engine is running After Heat Air Heater is on when the coolant temperature is less than 45 C 113 F maximum 10 minutes 7 minutes while engine is running Time Time Air Heater A...

Page 280: ...e sensor When setting the starter switch to ENGINE ON the heater plug automatically turns on for 30 seconds when the coolant temperature is 10 C 50 F or less After the engine starts the heater plug stays on for a maximum of 10 minutes or until the coolant temperature reaches 45 C 113 F The heater plugs then cut off Figure 12 20 Figure 12 20 Figure 12 21 Figure 12 21 1 Heater Plug 2 Seal 3 Intercoo...

Page 281: ...rine International Heater Relay Figure 12 22 Figure 12 22 1 Use TYCO Connector Housing 282080 1 Seal 281934 2 Terminal 282110 1 2 Bolt Terminals M6 Torque 5 N m 44 lb in Maximum Heater Fuse Figure 12 23 Figure 12 23 1 Cover 2 Nut 3 Washer 4 Fuse 5 Bolt 6 Jam Nut 7 Base 2 1 0006286 1 2 3 4 5 6 7 0006287 ...

Page 282: ...8535 52120 2 10A IGNITION PANEL Switch panel Fuse box 198535 52120 3 20A ECU Fuse box 198535 52140 4 10A IGNITION SIG Switch ON signal Fuse box 198535 52120 5 5A YDT Fuse box 198535 52110 6 250A Air Heater A Below exhaust manifold 119578 77150 7 250A Air Heater B Below exhaust manifold 119578 77150 8 150A ALTERNATOR Below exhaust manifold 119578 77090 9 50A STARTER RELAY Below exhaust manifold 119...

Page 283: ...se Box Relay Assembly Under the Exhaust Manifold Figure 12 25 Figure 12 25 1 Starter Relay 2 Air Heater Relays 3 Alternator Fuse 150A 4 Air Heater Fuse 250A 5 Starter Fuse 50A Fuse Location Label for the Fuse Box Figure 12 26 Figure 12 26 1 Spare 2 10A 3 10A 4 20A 5 10A 6 5A 7 Fuse Puller 0006288 1 2 3 4 5 6 7 1 2 3 5 4 0006289 S P A R E S P A R E S P A R E S P A R E 10A AUX POWER 10A IGN PANEL 20...

Page 284: ...Harness D Starter Air Heater Connection between starter relay starter S terminal and heater fuses A B Harness E Starter Alternator Connection between starter B terminal and alternator fuse Harness F Starter Connection between starter relay and starter S terminal fuse Harness G Air Heater Connection between heater relays A B and heater A B Figure 12 27 Figure 12 27 1 Harness G Heater Relay Heater 2...

Page 285: ... International Figure 12 28 Figure 12 28 1 Oil Pressure Sensor 2 Harness ENG 3 Harness G Heater Relay Heater 4 Alternator 5 Boost Pressure Sensor 6 Fuel Temperature Sensor 7 Pump Speed Sensor 8 Fuse Box 9 Oil Temperature Sensor 10 Crankshaft rpm Sensor 11 Intake Air Heater 1 2 3 4 5 6 7 8 9 10 11 0006292 ...

Page 286: ... 29 1 the digital display Figure 12 29 4 the interface module Figure 12 29 5 and the control head Figure 12 29 3 which are connected by the wire harness to the engine electrical governor and marine gear Figure 12 29 7 for remote control operation Figure 12 29 Figure 12 29 1 1st Station Rocker Switch Panel 2 12 Pin Connector to Engine 3 Control Head Shift and Throttle 4 Digital Display 5 Interface ...

Page 287: ... can be shown Figure 12 31 Figure 12 31 Alarm Indicators The alarm window appears with audible alarms when a fault is detected A sample of the alarm window is shown in Figure 12 32 Figure 12 32 Figure 12 32 Alarm Log Screen A sample alarm log screen is shown in Figure 12 33 Figure 12 33 Figure 12 33 0006293 1 2 3 0 1 2 3 4 WTR TEMP X1000 RPM PSi 8 4 2615 0 100 100 250 11 4 Fah SINGLE OIL PRES 0006...

Page 288: ... and also limits the engine speed to 1800 rpm or less for engine protection Alarm Diagram at Oil Pressure Figure 12 34 Figure 12 34 Item ON OFF Oil Press Logging 1 See Figure 12 34 Coolant Temperature Alarm 100 C 212 F 95 C 203 F Engine protection 2 Log 1 110 C 230 F 105 C 221 F Oil Temperature Alarm 110 C 230 F 105 C 221 F Log 1 120 C 248 F 115 C 239 F Fuel Temperature Alarm 80 C 176 F 75 C 167 F...

Page 289: ...START Switch 3 Sub Throttle control If the main throttle control fails the sub throttle lamp Figure 12 35 1 will flash The engine speed is then controlled by using the sub throttle Figure 12 35 2 Engine speed increases when the sub throttle knob is turned clockwise When the sub throttle lamp flashes turn the sub throttle knob counterclockwise to the end and turn the knob clockwise gradually until ...

Page 290: ...ngage the split range throttle SRT optional SELECT or SEL SELECT Button This button allows the operator to activate or deactivate the current location as helm control in multiple control stations installations SYNC This button engages or disengages Power Train Synchronization PTS option if installed This is an option that will synchronize starboard and port engine rpm when the control head levers ...

Page 291: ...s Relays and Harnesses 13 21 Fuse Relay and Harness 13 21 Fuse Burns Out 13 21 Test Check 13 21 Checking a Fuse 13 21 Troubleshooting Blown Fuses 13 22 Electronic Control System 13 26 Engine Control System Diagram 13 26 Troubleshooting by DTC Fault Codes 13 28 TELEFLEX i5601E Display Alarm Screen Information 13 28 Terms 13 28 List of DTC Diagnostic Trouble Codes 13 30 Troubleshooting the Temperatu...

Page 292: ...TROUBLESHOOTING 13 2 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 293: ...Yanmar Marine International SAFETY PRECAUTIONS Before servicing the 6LY3 marine engines review the Safety Section on page 2 1 INTRODUCTION This section contains information and diagnostic troubleshooting charts to accurately diagnose an engine starter or alternator problem ...

Page 294: ... engine model and serial number 4 Get the vessel model and serial number in which the engine is installed 5 When was the last time the engine was serviced 6 How many hours of operation since the last service interval and what was done 7 Has the problem ever occurred before and what was the resolution 8 When did the symptom or failure happen 9 Did anything change or did anything unusual happen befo...

Page 295: ...digital display and the control head Low battery voltage no battery voltage Check the electrolyte level and the specific gravity of the battery liquid See Checking the Electrolyte Level on page 12 4 Charge the battery or replace See Charging the Battery on page 12 5 Check the wiring circuit See Alternator Wiring Diagram on page 11 8 Battery will not charge Check the wires between the alternator an...

Page 296: ...gram on page 11 8 Connectors are not closed Close the connector according to the manual See Remote Control Electronic Control System ECS on page 12 20 Contact failure of each connector pin Check each connector terminal and confirm continuity See Remote Control Electronic Control System ECS on page 12 20 Fuse burned out IGN PANEL 10A Replace the fuse See Troubleshooting Fuses Relays and Harnesses o...

Page 297: ...n page 11 8 Check the tension of V belt See Check the V Belt Tension on page 4 25 Check the alternator See Alternator on page 11 1 Fuse burned out IGN PANEL 10A Replace the fuse See Fuse Chart on page 12 16 and Troubleshooting Fuses Relays and Harnesses on page 13 21 Fuse burned out ECU 20A Replace the fuse See Fuse Chart on page 12 16 and Troubleshooting Fuses Relays and Harnesses on page 13 21 F...

Page 298: ...d Harnesses on page 13 21 Magnet switch contact failure Coil failure Burr on the tooth Repair or replace See Battery Cables on page 12 3 Clearance between the pinion and the ring gear Repair the clearance See Battery Cables on page 12 3 The pinion gear meshes but the starting motor does not rotate Loose battery or loose starting motor terminals Check the terminals If trouble is found repair See Ba...

Page 299: ...L position Starter Interlock Shift the lever to NEUTRAL position See Remote Control Electronic Control System ECS on page 12 20 Emergency stop switch is pressed Turn off the emergency stop See Remote Control Electronic Control System ECS on page 12 20 Crank speed sensor detects overspeed P0219 DTC See Troubleshooting Fuses Relays and Harnesses on page 13 21 Camshaft speed sensor detects overspeed ...

Page 300: ...n nozzle Valve seat Check the fuel spray condition If a malfunction is found send to the FIE shop for service or replace See Fuel Injection Nozzle Components and Functions on page 6 26 Needle valve Wear of nozzle seat Clogged fuel nozzle hole s Nozzle opening pressure Faulty fuel injection pump Wear of plunger Check If a malfunction is found send it to the FIE shop for service or replace If measur...

Page 301: ...e See Replacing the Piston Rings on page 5 39 Sticking of the piston ring s Disassemble and check If sticking is found clean or replace See Replacing the Piston Rings on page 5 39 Loose cylinder head bolts Torque to specifications See Cylinder Head Components and Functions on page 5 26 Damaged valve spring If damaged replace See Checking the Valve Springs on page 5 32 Air heater does not operate A...

Page 302: ...gine cannot be controlled Engine speed does not rise to more than 1800 rpm Crankshaft speed sensor error Detected error P0335 DTC See Troubleshooting by DTC Fault Codes on page 13 28 Camshaft speed sensor error Detected error P0340 DTC See Troubleshooting by DTC Fault Codes on page 13 28 Difference error of speeds Detected error P0335 DTC See Troubleshooting by DTC Fault Codes on page 13 28 Discon...

Page 303: ...peration by sub throttle Check the input value of the acceleration sensor with a YDT If an error is not detected check the signal voltage of the sub throttle sensor If failure is found correct or replace the wire harness or sub throttle sensor Refer to the YDT Manual Refer to Figure 13 1 on page 13 14 Error of rack position sensor Detected error P1201 DTC See Troubleshooting by DTC Fault Codes on ...

Page 304: ...ng by Symptom 13 14 6LY3 Service Manual 2007 Yanmar Marine International Figure 13 1 Figure 13 1 5 0 4 58 0 42 4 5 4 0 3 5 3 0 2 5 Single Voltage V Rotation Angle Degree 2 0 1 5 1 0 0 5 0 0 0 20 40 60 80 100 120 140 160 180 0006110 ...

Page 305: ...on page 6 26 Sticking needle valve Wear of seat Clogged fuel injection hole s A decrease in fuel opening pressure Uneven fuel injection volume Faulty movement of the fuel injection pump plunger Check If a malfunction is found send it to the FIE shop for service or replacement If measuring lag with a YDT the movement of the rack can be checked Refer to the YDT Manual Damaged fuel injection pump plu...

Page 306: ...ge 6 33 Damaged fuel lines Check the fuel system and repair See Fuel System Diagram on page 6 6 Faulty fuel feed pump Check the feed pump and repair or replace See Fuel Feed Pump Components and Functions on page 6 28 Seized main moving part s Repair or replace if necessary See Engine on page 5 1 Clogged air cleaner Clean or replace See Fuel System on page 6 1 Engine does not stop Fuel injection pu...

Page 307: ...rminal Check around the terminal and repair if necessary See Fuse Relay and Harness Components on page 12 16 Faulty air heater Disassemble and check Replace if necessary See Air Heater Operation on page 12 13 Faulty air heater relay Check the relay with a YDT and tester Replace if necessary See Fuse Relay and Harness Components on page 12 16 Fuse burned out Air heater A or B 250A Replace See Troub...

Page 308: ...ry See Inspecting the Pistons and Piston Pins on page 5 36 Wear of the piston rings Check and replace See Measuring the Pistons on page 5 37 Sticking piston rings Check clean and replace See Measuring the Pistons on page 5 37 Scarring or wear of the cylinder wall Disassemble and check Repair or replace if necessary See Inspecting the Cylinder Block and Components on page 5 22 Insufficient amount o...

Page 309: ... for a clogged seawater line and for dirt in the intercooler core See Seawater Pump Components and Functions on page 7 6 Engine room is not ventilated Check the ventilation Faulty combustion because of the blow by gas and the decreased compression air pressure No valve clearance Readjust the valve clearance See Service Standards on page 14 3 Faulty contact of the intake exhaust valves and seats La...

Page 310: ...hop for maintenance See Fuel Injection Pump Governor Timer on page 6 7 Insufficient intake air volume Clogged air cleaner Clean or replace See Troubleshooting the Fuel Injection System on page 6 24 Decrease in intake air pressure Check the turbocharger Clean the blower of turbocharger See Turbocharger Components and Functions on page 9 4 Intake air temperature is too high Check the impeller of the...

Page 311: ...s out again replace the harness Test Check Check the continuity by touching the corresponding fuse terminal to the ground In the case of a fuse on a relay assembly open the fuse cover and check the continuity by touching the corresponding fuse terminal to ground Checking a Fuse 1 Remove the fuse 2 Check between both terminals for continuity 3 If continuity is indicated the fuse is in good conditio...

Page 312: ...ine harness may have a short circuit Remove the harness 12 pin connector above the fuel injection pump and check for continuity again See Wire Harness Locations on page 12 18 In case of continuity the engine harness has a short circuit Replace it In case of no continuity the TELEFLEX harness may have a short circuit Replace it 3 20A ECU The engine will not start ECU will not turn on The engine shu...

Page 313: ...y replace the fuse If the fuse burns out again the main harness may have a short circuit Replace it 7 150A ALTERNATOR Engine runs normal Engine runs normal Battery discharge Off Check the continuity between the negative side of the fuse and ground See Wire Harness Locations on page 12 18 In case of continuity harness A may have a short circuit Replace it See Wire Harness Locations on page 12 18 In...

Page 314: ...continuity remove the TELEFLEX extension harness from the connector of switch panel Check the pins of the TELEFLEX extension harness in the same manner 10 5A IGN SIG 2nd Station Engine will not start ECU inoperative Engine shuts down and will not start from 1st station On Check the continuity between the negative side of the fuse and ground See Wire Harness Locations on page 12 18 In case of no co...

Page 315: ...nnector Figure 13 3 Figure 13 3 1 0006116 No Connector Destination Remarks 1 Blank Waterproof plug 2 5V sensor Power supply for sub throttle sensor 3 1st station ON 12V energized by ON 4 Battery 12V 12V always from the battery 5 Emergency stop Emergency stop Return 6 Sub throttle sig Sub throttle voltage 7 Sensor ground 8 Reserved Unused though there is a line 9 2nd station ON 12V energized by ON ...

Page 316: ...d an electro hydraulic timer These components are attached to the fuel injection pump control fuel injection quantity and injection timing electronically Engine Control System Diagram The ECU controls fuel injection quantity and injection timing by interpreting engine operating parameters such as throttle positions gear shift selections and control panel displays It monitors engine conditions such...

Page 317: ...and YDT Figure 13 5 Figure 13 5 YDT YDT 2nd Helm 1st Helm NMEA 2000 or or Helm ECU Helm ECU or Helm ECU J1939 Power Battery Fuel Tank Neutral Safety Start SW F N R Electrical Gear Inboard Sub Throttle Sensor E C U J1939 Power Battery Fuel Tank Neutral Safety Start SW F N R Electrical Gear Inboard Sub Throttle Sensor E C U 0006318 ...

Page 318: ...ayed on the TELEFLEX display TELEFLEX i5601E Display Alarm Screen Information Terms DTC Diagnostic Trouble Code FMI Failure Mode Identifier HOT ENGINE CHECK ENGINE OVER REV EMERGENCY STOP OIL PRESSURE LOW VOLTAGE TURBO BOOST ALTERNATOR GEAR OIL SEAWATER FLOW ENG COM ERROR LOW COOLANT MAINTENANCE WATER IN FUEL NETWORK MAIN THROTTLE PWR REDUCTION SEC THROTTLE NEUTRAL PROTECT SHUTTING DOWN ...

Page 319: ... use of some of these features Changing the basic set up is typically accomplished in one of two ways 1 Go to the systems menu and alter basic selections 2 Enable the right arrow key on the basic screens to allow changing of the data shown in the default displays To move around the menus use the softkeys at the bottom of the screen The function of a particular softkey changes from screen to screen...

Page 320: ...o Calibration Press the right arrow button then go to User Setting menu The arrow should be at the Reset Maint Time selection Press the right arrow key to reset The warning will go away After an additional 250 hours of operation the maintenance warning will be displayed again and every 250 hours thereafter This a reminder that periodic maintenance must be performed at these intervals This screen d...

Page 321: ...uel Temperature Sensor P0183 2 Oil Temperature Too High P0195 2 Oil Temperature Sensor P0198 2 Oil Temperature Too High P0216 3 Injection Timing Control Device P0219 1 Crank Cam Over Revolution P0220 2 Sub Throttle Sensor P0234 2 Over Boost P0235 2 Boost Pressure Sensor P0335 0 2 Cam Crank Speed Incompatibility P0335 4 2 Crank Speed Sensor P0340 2 Cam Speed Sensor P0520 2 Oil Pressure Sensor P0522...

Page 322: ...TROUBLESHOOTING Troubleshooting by DTC Fault Codes 13 32 6LY3 Service Manual 2007 Yanmar Marine International Wiring Diagram Figure 13 9 Figure 13 9 0006419 ...

Page 323: ... Timer Solenoid 3 Advance Timer Solenoid 4 Air Heater Relay 1 5 Air Heater Relay 2 6 Crank Speed Sensor Pulse 7 Cam Speed Sensor Pulse 8 Starter ON 9 Sub Throttle Switch 10 2nd Station Key 11 ECU Power GND 12 ECU Main Relay 13 14 Actuator Relay 15 12V DC 16 Crank Speed Sensor Pulse 17 Cam Speed Sensor Pulse 18 Neutral Switch 19 1st Station Key 20 Emergency Stop 21 Starter Check 22 Sub Throttle Ind...

Page 324: ...igure 13 11 Figure 13 11 Electrical Circuit Chart Figure 13 12 Figure 13 12 Part Code 119254 44910 1 Coolant Temperature Sensor DTC P0115 3 4 Coolant Temperature Sensor 0 1 1 10 100 40 C 20 C 0 C 20 C 40 C 60 C 80 C 100 C 120 C 40 F 4 F 32 F 68 F 104 F 140 F 176 F 212 F 248 F 0006118 Temperature Sensor Characteristics Typical Resistance K Ohms Temperature A B 37 35 ECU 1 0006159 M12 x 1 5 59 19 00...

Page 325: ...age is below 0 2V 3 0 5 seconds 4 CHECK ENGINE on the TELEFLEX display Wire harness sensor Fail Mode Engine takes following coolant temperature as a default 15 C 5 F at engine stop for starting 60 C 140 F at engine running Limited Operation No limited operation Fail Release Yes When input signal voltage goes to normal range 0 2 4 8 V for 0 5 seconds Remarks White smoke increases in cold conditions...

Page 326: ... Temperature Too High DTC FMI 1 Condition 2 Fault 3 Time to Detect 4 Display Check Point P0118 0 1 Key switch ON 2 Coolant temperature above 110 C 230 F 3 0 5 seconds 4 HOT ENGINE PWR REDUCTION on the TELEFLEX display Coolant system Seawater system Sensor Fail Mode Engine over heat condition results in limited operation Limited Operation Maximum engine speed is limited to 1800 rpm Fail Release Yes...

Page 327: ...ng If the sub throttle is selected the lamp turns on Once the sub throttle is selected the sub throttle keeps working even if the main throttle would go back to normal Limited Operation Yes 1 If the sub throttle is selected Sub throttle is active 2 If the sub throttle is inactive Engine speed is fixed at low idle or 1000 rpm Idle in Neutral and 1000 rpm in Forward Reverse Fail Release Yes When ECU...

Page 328: ... Sensor Specification Chart Figure 13 13 Figure 13 13 Electrical Circuit Chart Figure 13 14 Figure 13 14 Part code 119254 44910 1 Fuel Temperature Sensor DTC FMI Probable Cause P0120 0 1 Teleflex wire harness in the throttle control head unit 2 Teleflex throttle head malfunction DTC P0180 3 4 Fuel Temperature Sensor 0 1 1 10 100 40 C 20 C 0 C 20 C 40 C 60 C 80 C 100 C 120 C 40 F 4 F 32 F 68 F 104 ...

Page 329: ... P0180 4 1 Key switch ON 2 Input signal voltage is below 0 2V 3 0 5 seconds 4 CHECK ENGINE on the TELEFLEX display Wire harness sensor Fail Mode Engine takes the following fuel temperature as a default 50 C 122 F Above value can be monitored with a YDT Diagnostic Test Analog Input Fail Release Yes When the input signal voltage goes to normal range 0 2 4 8V for 0 5 seconds Limited Operation No limi...

Page 330: ...Figure 13 16 Figure 13 16 Part code 119254 44910 1 Temperature Sensor 2 Temperature Output 3 Sensor Ground DTC FMI Content PIN of ECU PIN of ECU P0115 3 4 Coolant Temperature Sensor 37 35 P0180 3 4 Fuel Temperature Sensor 28 35 P0195 3 4 Oil Temperature Sensor 39 35 0 1 1 10 100 40 20 0 20 40 60 80 100 120 0006141 Temperature Sensor Characteristics Typical Resistance K Ohms Temperature C ECU_TH EC...

Page 331: ...Sensor Check sensor performance resistance 2 Wire harness Check ECU output voltage of harness Use breakout box Disconnect the connector of sensor Replace sensor NG OK NG 3 Wire harness Check wire harness open short OK Replace wire harness NG OK 4 Wire harness Check sensor conductivity NG OK Replace ECU Replace ECU or sensor Replace ECU 0006144 ...

Page 332: ...ECU connector connected to the ECU Turn the key to ON and supply power to the ECU Measure the voltage Check the voltage between the terminals of the wire harness connector 3 Checking the wire harness open short circuit Disconnect the ECU connector from the ECU and unplug the sensor connector Use an electric tester to check for an open short circuit in the wire harness continuity C 5V sensor supply...

Page 333: ...ranch harness and connector from each pin of ECU The tester probe can be inserted here and the voltage and the waveform between each ECU pin can be measured 2 Breakout Box and Harness 3 Engine Harness ECU_G_S other terminal ECU Pin 35 Defective OK Normal Good Failure Open circuit Terminals Continuity Status Failure 1 Check the wire harness 2 Replace the wire harness OK Check the sensor voltage out...

Page 334: ...ct 4 Display Check Point P0183 0 1 Key switch ON 2 Fuel temperature is above 90 C 194 F 3 0 5 seconds 4 CHECK ENGINE on the TELEFLEX display FO system FO sensor Fail Mode Fuel temperature exceeds the acceptable range for the fuel system Limited Operation No limited operation Fail Release Yes When the fuel temperature goes below 85 C 185 F Remarks Normal fuel temperature is about 40 C 104 F at the ...

Page 335: ...e 13 19 Figure 13 19 Electrical Circuit Chart Figure 13 20 Figure 13 20 Part code 119254 44910 1 Oil Temperature Sensor DTC P0195 3 4 Oil Temperature Sensor 0 1 1 10 100 0006123 4 F 40 C 20 C 0 C 20 C 40 C 60 C 80 C 100 C 120 C 40 F 32 F 68 F 104 F 140 F 176 F 212 F 248 F Temperature Sensor Characteristics Typical Resistance K Ohms Temperature A B 39 35 ECU 1 0006124 59 19 0006125 ...

Page 336: ...the TELEFLEX display Wire harness sensor P0195 4 1 Key switch ON 2 Input signal voltage is below 0 2V 3 0 5 seconds 4 CHECK ENGINE on the TELEFLEX display Wire harness sensor Fail Mode Engine takes the following oil temperature as a default 90 C 194 F Limited Operation No limited operation Fail Release Yes When the input signal voltage goes to normal range 0 2 4 8V Remarks DTC FMI Probable Cause P...

Page 337: ...rature Too High DTC FMI 1 Condition 2 Fault 3 Time to Detect 4 Display Check Point P0198 0 1 Key switch ON 2 Oil temperature is above 120 C 248 F 3 0 5 seconds 4 CHECK ENGINE on the TELEFLEX display Oil system Cooling seawater system sensor Fail Mode Limited Operation No limited operation Fail Release Yes When the oil temperature goes below 115 C 239 F for 0 5 seconds Remarks Normal oil temperatur...

Page 338: ...arine International P0216 7 Injection Timer Device Figure 13 21 Figure 13 21 1 Electromagnetic Valve 2 Helical Spline 3 Piston 4 Straight Spline 5 Cam Tightening Nut 6 Cylinder 7 Pump Drive Gear 8 Pump Camshaft 9 Cam Drive Coupling DTC P0216 7 Injection Timer Device 6 1 7 2 3 4 9 8 5 0006126 ...

Page 339: ...ositions replace the fuel injection pump FIP and the timer device May have some mechanical problems within the injection timing device DTC FMI 1 Condition 2 Fault 3 Time to Detect 4 Display Check Point P0216 7 1 Engine running 2 Does not meet target value of the injection timer phase 3 10 seconds 4 PWR REDUCTION CHECK ENGINE on the TELEFLEX display Timer device speed sensor Oil system Timer soleno...

Page 340: ...eck the fuel injection pump lag rack actuator performance If lag results in fault replace the fuel injection pump including position sensor amplifier DTC P0219 0 Engine Over Revolutions DTC FMI 1 Condition 2 Fault 3 Time to Detect 4 Display Check Point P0219 0 1 Engine running 2 Engine speed of the cam or crank exceeds 3900 rpm 3 4 OVER REV on the TELEFLEX display Injector FIP Crank cam speed sens...

Page 341: ...ay Wire harness sensor P0220 4 1 Key switch ON 2 Input signal voltage to the ECU from the sub throttle sensor is below 0 2V 3 0 5 seconds 4 SEC THROTTLE on the TELEFLEX display Wire harness sensor Fail Mode Fail mode will be different according to the position of the main throttle 1 If the sub throttle is active Target engine speed slows to low idle speed Target speed is set to low idle in neutral...

Page 342: ... 0 1 Key switch ON 2 Boost pressure is above 250 kPa 36 psi 3 0 5 seconds 4 PWR REDUCTION the TURBO BOOST on the TELEFLEX display Turbocharger boost pressure sensor Fail Mode Turbocharger over boost condition Limited Operation Maximum engine speed is limited to 1800 rpm Fail Release Yes When boost pressure is below 200 kPa 29 psi Limited Operation Release Yes After failure is cleared and also when...

Page 343: ...ure 13 23 Figure 13 23 1 Boost Pressure Sensor 2 Supply Voltage 5V 3 Signal 4 Ground 5 ECU Figure 13 24 Figure 13 24 Part code 119578 91300 1 Ground 2 Signal Output 3 5V Sensor DTC P0235 3 4 Turbocharger Boost Pressure Sensor 0 0 5 1 1 5 2 2 5 3 3 5 4 0 200 400 600 800 1000 1200 0 50 100 150 0006127 5V Pressure Sensor Characteristics Sensor Output Voltage Pressure kPa 5 24 1 2 3 40 35 1 5 2 3 4 00...

Page 344: ...st pressure sensor Fail Mode Engine takes the following boost pressure as a default 0 kPa 0 psi Limited Operation Maximum engine speed is limited to 1800 rpm Fail Release Yes When the input signal voltage goes to normal range 0 5 3 6V Limited Operation Release Yes After failure is cleared and also when throttle position is at low idle position Remarks Sensor supply voltage must be kept below 6V On...

Page 345: ...LEFLEX display Wire harness Crank speed sensor Cam speed sensor Fail Mode Engine will keep controlling the engine speed with the cam signal ECU uses crank speed as normal condition Engine cannot control the injection timer and have the failure code of the injection timer control with the injection timing fully retarded Limited Operation Maximum engine speed is limited to 1800 rpm Fail Release Yes ...

Page 346: ...peed Sensor Electrical Circuit Chart Figure 13 25 Figure 13 25 1 Crank Speed Sensor 2 ECU Figure 13 26 Figure 13 26 Part Code 158557 61720 1 Core 2 Magnet 3 O Ring 4 Yoke 5 Coil Bobbin Comp 6 Sensor Body 7 Bushing 8 Epoxy Tape 9 Coil DTC P0335 4 Crank Speed Sensor CRK CRK B A CRK 6 CRK 16 1 2 0006130 1 2 3 4 5 6 7 8 9 0006331 ...

Page 347: ...peed as normal condition Engine cannot control the injection timer and have the failure code of the injection timer control with the injection timing fully retarded Limited Operation Maximum engine speed is limited to 1800 rpm Fail Release Yes When the difference between the cam and crank speed is within 15 rpm Limited Operation Release Yes After the fault has been cleared and also when the thrott...

Page 348: ...Speed Sensor Electrical Circuit Chart Figure 13 27 Figure 13 27 Figure 13 28 Figure 13 28 Part code 158557 61720 1 Core 2 Magnet 3 O Ring 4 Yoke 5 Coil Bobbin Comp 6 Sensor Body 7 Insert Bush 8 Epoxy Tape 9 Coil DTC P0340 4 Cam Speed Sensor CAM CAM B A CAM 7 CAM 17 FOP Cam Speed Sensor ECU 0006326 1 2 3 4 5 6 7 8 9 0006331 ...

Page 349: ...Fail Mode Engine will keep controlling engine speed with the crank signal Engine cannot control the injection timer during and injection failure code The injection timing will default to fully retarded Limited Operation Maximum engine speed is limited to 1800 rpm Fail Release Yes When the difference between cam and crank speed is within 15 rpm Limited Operation Release Yes After the fault has been...

Page 350: ... Figure 13 30 Figure 13 30 1 Oil Pressure Sensor 2 Supply Voltage 5V 3 Signal 4 Ground 5 ECU Figure 13 31 Figure 13 31 Part code 119578 91300 1 5V Sensor 2 Signal Output 3 Ground DTC P0520 3 4 Oil Pressure Sensor 0 0 5 1 1 5 2 2 5 3 3 5 4 0 200 400 600 800 1000 1200 0 50 100 150 0006132 5V Pressure Sensor Characteristics Sensor Output Voltage Pressure kPa 5 24 1 2 3 27 35 1 2 5 3 4 0006133 3 2 1 P...

Page 351: ...n the TELEFLEX display Wire harness Sensor Fail Mode Limited Operation No limited operation Fail Release Yes When the input signal voltage goes to normal range 0 2 3 6V Remarks Oil pressure is monitored for engine diagnosis use only Sensor supply voltage must be kept below 6V Once the sensor supply voltage exceeds 6V sensor damage occurs Replace the pressure sensor To check if the voltage has been...

Page 352: ...2 Judgement 3 Time to Detect 4 Display Check Point P0522 1 1 Key switch ON 2 Oil pressure is below the standard compared to the engine speed 20 kPa 1000 rpm 29 psi 1000 rpm 200 kPa 3000 rpm 2 9 psi 3000 rpm 3 0 5 seconds 4 OIL PRESSURE on the TELEFLEX display Oil system Fail Mode Limited Operation No limited operation Fail Release Yes When the oil pressure goes over the normal value Remarks May da...

Page 353: ...e to Detect 4 Display Check Point P0562 0 1 Key switch ON 2 ECU supply voltage is above 16V 3 2 5 seconds 4 CHECK ENGINE on the TELEFLEX display Battery Alternator Wire harness P0562 1 1 Key switch ON 2 ECU supply voltage is above 9V 3 2 5 seconds 4 LOW VOLTAGE on the TELEFLEX display Battery Alternator Wire harness Fail Mode Limited Operation No limited operation Fail Release Yes When the input s...

Page 354: ...lt 3 Time to Detect 4 Display Check Point P0605 12 1 Key switch ON 2 ECU detects EEPROM device error 3 4 CHECK ENGINE on the TELEFLEX display ECU Fail Mode Limited Operation No limited operation Fail Release No Remarks Other DTC and some engine information cannot be indicated while this DTC is occurring Example Engine Run Hours Require key off to reset the fail mode DTC FMI Probable Cause P0605 12...

Page 355: ...r Marine International P1202 0 1 Rack Position Sensor Electrical Circuit Chart Figure 13 33 Figure 13 33 1 Control Rack 2 Timer 3 Fuel Injection Pump 4 Governor 5 Rack Position Sensor 6 Governor Solenoid 7 Fuel Decrease 8 Fuel Increase DTC P1202 0 1 Rack Position Sensor 1 2 3 4 5 6 7 8 0006136 ...

Page 356: ...n pump Rack position sensor Rack actuator Wire harness Fail Mode Engine keeps running with rack control failure code Injection timing is controlled in rack control failure mode Target rack position and actual rack position will be indicated as 0 by the YDT Engine load is indicated 0 on the TELEFLEX display and on the YDT Limited Operation Maximum engine speed is limited to 1800 rpm Fail Release No...

Page 357: ...P1210 4 Rack Actuator DTC FMI 1 Condition 2 Fault 3 Time to Detect 4 Display Check Point P1210 4 1 Key switch ON 2 Abnormally high engine speed rpm 3 Uncontrollable rack actuator 4 0 1 seconds 5 CHECK ENGINE on the TELEFLEX display Wire harness Rack actuator Fail Mode Engine stops because the rack position is set to the stop position Turn off the rack actuator relay Limited Operation Engine stop F...

Page 358: ...chanical Malfunction DTC FMI 1 Condition 2 Fault 3 Time to Detect 4 Display Check Point P1211 7 1 Key switch ON 2 Abnormal acceleration of engine speed is caused by a rack actuator malfunction 3 1 second 4 CHECK ENGINE on the TELEFLEX display Rack actuator Fuel injection pump Wire harness Fail Mode Engine stops because the rack position is set to the stop position Turn off the rack actuator relay ...

Page 359: ... Manual 13 69 2007 Yanmar Marine International P1220 7 P1225 7 Advance Retard Timer Solenoid Figure 13 34 Figure 13 34 1 Timer Solenoid Figure 13 35 Figure 13 35 1 Electromagnetic Valve DTC P1220 7 Advance Timer Solenoid P1225 7 Retard Timer Solenoid 1 0006137 1 0006311 ...

Page 360: ... by DTC Fault Codes 13 70 6LY3 Service Manual 2007 Yanmar Marine International Electrical Circuit Chart Figure 13 36 Figure 13 36 3 B A 2 C A B 20A ECU Battery Fuse Main Relay Advance Timer Solenoid ECU Retard Timer Solenoid 0006138 ...

Page 361: ...failure code The injection timing will default to fully retarded Limited Operation Maximum engine speed is limited to 1800 rpm Fail Release No Remarks Require key off to reset fail mode White smoke or black smoke may increase more than usual because of a failure code of the injection timing control This DTC is for open or short status of wire harness and timer solenoid Timer device malfunctions ar...

Page 362: ...n the TELEFLEX display Wire harness Sensor ECU Fail Mode ECU cannot get boost pressure value and defaults to limited operation condition Limited Operation Maximum engine speed is limited to 1800 rpm Fail Release Yes When the sensor voltage goes to normal range 4 5 5 5V Remarks 5V sensor affects all pressure sensors and sub throttles P1230 0 or 1 cannot detect an open circuit in 5V sensor wire harn...

Page 363: ...OUT2 OUT1 RPS B2 SNS5 CAMP STHL STR EMS B1 RAR STSW MNR G P IGN2 STHS ST CAM CRK AHR2 AHR1 TAAD TARD RA IGN1 NTS CAM CRK STH THF PLO CANL THLO AN1 THW CANH 1 11 21 31 10 20 30 40 30 25 24 23 22 21 20 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 19 18 17 16 29 28 27 26 40 35 34 33 32 31 39 38 37 36 0006139 DTC FMI 1 Condition 2 Fault 3 Time to Detect 4 Display Check Point P1240 0 1 Key switch ON 2 ECU diagn...

Page 364: ...ECU Temperature Too High DTC FMI 1 Condition 2 Fault 3 Time to Detect 4 Display Check Point P1603 0 1 Key switch ON 2 ECU temperature is higher than 85 C 185 F 3 0 5 seconds 4 CHECK ENGINE on the TELEFLEX display Cooling freshwater seawater system Environment around the ECU engine room temperature Fail Mode Limited Operation No limited operation Fail Release Yes After the fault has been cleared an...

Page 365: ...ne International U0146 12 i2 Model i83XX Communication Error Electrical Circuit Chart Figure 13 39 Figure 13 39 DTC U0146 12 i2 module i83XX communication error i2 module communication error CANH CANL 3 6 CANL 26 CANH 36 2 BAT BAT 8 4 20A ECU 0006140 Battery AUX Power Service Tool Fuse Main Relay ECU ...

Page 366: ... throttle is selected the lamp turns on Once the sub throttle is selected the sub throttle keeps working even if the i2 module communication would go back to normal Limited Operation Main throttle fail mode Fail Release Yes i2 module communication error Limited Operation Release Main throttle fail release 1 If the sub throttle is active No 2 If the sub throttle is inactive Yes After the U0146 fail...

Page 367: ...ensor 5V 2 Signal Output 3 Ground DTC FMI Content PIN of ECU_VSEN PIN of ECU_PRS PIN of ECU_G_S P0235 3 4 Boost Pressure Sensor 24 SNS5 40 PBST 35 G_S P0520 3 4 Oil Pressure Sensor 24 SNS5 27 PLO 35 G_S 0 0 5 1 1 5 2 2 5 3 3 5 4 0 200 400 600 800 1000 1200 0 50 100 150 Pressure Sensor Characteristics Sensor Output Voltage V Pressure kPa 5 0006145 SNS5 ECU_P ECU_S 24 1 2 3 PLO 27 PBST 40 35 ECU Pre...

Page 368: ...r all the sensors on the same circuit NOTICE Before replacing the wire harness check all of the connectors and the ECU 1 Sensor 5V Checking sensor 5V output OK NG 4 Wire harness Checking sensor 5V wire harness open short OK Exchange wire harness NG 3 Sensor Checking sensor performance NG OK Exchange ECU Exchange sensor Exchange ECU 2 Wire harness Checking wire harness open short S 5V Prs sig S GND...

Page 369: ...pply voltage to the ECU Measure the voltage Use the breakout box Terminals Voltage Status Wire harness connector 1 3 5V OK Normal Go to 2 Check wire harness for an open short not 5V Failure Go to 4 Check 5V sensor wire harness open short Terminals Continuity Status ECU_P B Good OK Normal Defective Failure Open circuit ECU_SNS5 C Good OK Normal Defective Failure Open circuit ECU_G_S A ground 11 33 ...

Page 370: ...ls Value A B pressure sensor connector 0 5V engine stopped A C pressure sensor connector 5V Wire harness is already checked at 1 Defective Replace the pressure sensor Replace the ECU if the pressure sensor replacement does not make a difference OK Replace the ECU Terminals Voltage Status Wire harness connector A B Below 0 5V Just below 0 5V may be an error Failure 1 Open circuit B ECU_P 2 Open cir...

Page 371: ... Actuator Relay Emergency Switch Rack Position Sensor Sub Throttle Indicator Emergency Throttle Position Sensor Starter Interlock Relay Starter Alternator Main Relay 1st Station Relay 2nd Station Relay NEUTRAL Switch Air Heater Figure 13 44 Figure 13 44 2B 1A 1B AHR1 4 AHR1 2A 2B 1A 1B AHR2 5 AHR2 2A 250A 250A 0006151 Air Heater Relay 1 Air Heater Relay 2 Air Heater 1 Air Heater 2 Battery Fuse Fus...

Page 372: ...Y3 Service Manual 2007 Yanmar Marine International Rack Actuator Rack Actuator Relay Emergency Switch Figure 13 45 Figure 13 45 BAT RAR A C RAR 14 EMS 20 B D 20A RA 1 B C Battery FOP Actuator Relay FOP Actuator Fuse Main Relay Emergency Stop Switch ECU 0006152 ...

Page 373: ...t Codes 12 05 6LY3 Service Manual 13 83 2007 Yanmar Marine International Rack Position Sensor Figure 13 46 Figure 13 46 RPS 30 RPS H E BAT G_S G_S A 35 J B G C D A H G F E 20A Rack Sensor Amplifier 0006153 Battery Fuse Main Relay ECU FOP Sensor ...

Page 374: ... 2007 Yanmar Marine International Sub Throttle Indicator Emergency Throttle Position Sensor Figure 13 47 Figure 13 47 STHL ECU 20A 22 STHL 10 12 B1 2 SNS5 STH G_S SNS5 STH G_S 24 2 6 7 29 35 Battery Fuse Main Relay ECU Sub Throttle Position Sensor Sub Throttle Indicator 0006154 ...

Page 375: ... Yanmar Marine International Starter Interlock Relay Starter Alternator Figure 13 48 Figure 13 48 STR 21 A C ST 8 B D STR BAT ECU ECU Key Switch Starter Interlock Relay Alternator ST 10A 2A 1A 1B 2B B S 50 A B L 120 A 20 A 2 0006155 Battery Fuse Fuse Fuse Starter Relay Starter Main Relay ...

Page 376: ...Main Relay 1st Station Relay 2nd Station Relay Figure 13 49 Figure 13 49 C 25 B 5A Key SW1 G_P1 2 A C IGN1 19 10 A 20 A B1 15 B2 A C IGN2 10 5A Key SW2 G_P1 2 BAT MNR 10 A D B D A B D MNR 12 0006156 Battery Fuse Fuse Fuse 2nd Station Relay 1st Station Relay ECU Main Relay Fuse Fuse ECU Key Switch 1 Key Switch 2 ...

Page 377: ...TROUBLESHOOTING Troubleshooting by DTC Fault Codes 12 05 6LY3 Service Manual 13 87 2007 Yanmar Marine International Neutral Switch Figure 13 50 Figure 13 50 G_P1 2 2A 1A ECU NTS 18 NTS 0006157 ...

Page 378: ...TROUBLESHOOTING Troubleshooting by DTC Fault Codes 13 88 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 379: ...tion 14 SERVICE STANDARDS Page Service Standards 14 3 Engine 14 3 Cylinder Head 14 4 Camshaft and Gear Train 14 5 Cylinder Block 14 6 Piston and Ring 14 7 Connecting Rod 14 9 Tightening Torque for Bolts and Nuts 14 10 Main Bolt and Nut 14 10 Standard Bolts and Nuts Without Oil 14 11 ...

Page 380: ...SERVICE STANDARDS 14 2 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 381: ...Press 36 96 38 34 MPa 377 391 kgf cm2 5560 psi 4 Coolant Capacity Engine 28 L 7 4 gal 7 4 Coolant Recovery Tank 1 5 L 0 4 gal 5 Oil Capacity full at a 0 rake angle Engine 18 8 L 5 gal 4 6 6 Oil Pressure 0 40 0 50 MPa 4 1 5 1 kgf cm2 58 72 psi 8 8 7 Oil Pressure Alarm ON 1000 rpm 20 kPA or less 2 9 psi 4 8 3000 rpm 200 or less kPa 29 psi 8 Thermostat Valve Opening Temperature 69 73 C 156 163 F 4 30...

Page 382: ...139 in 7 90 mm 0 3110 in Clearance 0 035 0 065 mm 0 0013 0 0025 in 0 18 mm 0 0070 in Exhaust Guide Inside Diameter 8 015 8 030 mm 0 3155 0 3161 in 8 1 mm 0 3188 in Valve Stem Outside Diameter 7 955 7 970 mm 0 3131 0 3137 in 7 90 mm 0 3110 in Clearance 0 045 0 075 mm 0 0017 0 0029 in 0 18 mm 0 0070 in Valve Guide Projection Intake 9 0 9 5 mm 0 3543 0 3740 in 5 32 Exhaust 7 0 7 5 mm 0 2755 0 2952 in...

Page 383: ... in 48 110 mm 1 8940 in Camshaft and Bearing Bushing Inside Diameter 56 980 57 050 mm 2 2433 2 2460 in 57 130 mm 2 2492 in 5 48 Camshaft Outside Diameter 56 910 59 940 mm 2 2405 2 3598 in 56 880 mm 2 2393 in Clearance 0 040 0 130 mm 0 0015 0 0051 in 0 240 mm 0 0094 in Inspection Item Standard Limit Reference Page Idle Shaft Diameter 53 950 53 975 mm 2 1240 2 1249 in 53 88 mm 2 1212 in 5 51 Idler G...

Page 384: ... Crank Pin Bearing Inside Diameter 65 000 65 045 mm 2 5590 2 5608 in 65 100 mm 2 5629 in 5 42 5 46 Pin Outside Diameter 64 952 64 964 mm 2 5571 2 5576 in 64 902 mm 2 5551 in Bearing Thickness 1 987 2 000 mm 0 0782 0 0787 in Clearance 0 036 0 093 mm 0 0014 0 0036 in 0 160 mm 0 0062 in Crank Journal Bearing Inside Diameter 75 000 75 045 mm 2 9527 2 9545 in Journal Outside Diameter 74 952 74 964 mm 2...

Page 385: ...4 1651 4 1653 in MS 105 789 105 794 mm 4 11651 4 1653 in S 105 779 105 789 mm 4 1645 4 1649 in Clearance Between Piston and Cylinder 0 111 0 131 mm 0 0043 0 0051 in Piston Diameter Measure Position Upward from the bottom end of the piston 22 mm 0 8661 in Piston Pin Hole Inside Diameter 37 025 37 040 mm 1 4576 1 4582 in 37 100 mm 1 4606 in 5 38 Piston Pin Outside Diameter 36 994 37 000 mm 1 4564 1 ...

Page 386: ...ap 0 30 0 50 mm 0 0118 0 0196 in 1 5 mm 0 0590 in Second Ring Ring Groove Width 2 570 2 585 mm 0 1082 0 1017 in 2 140 mm 0 0842 in Ring Width 2 470 2 490 mm 0 0972 0 0980 in 1 950 mm 0 0767 in Side Clearance 0 080 0 115 mm 0 0031 0 0045 in 0 200 mm 0 0078 in Gap 0 50 0 70 mm 0 0196 0 0275 in 1 5 mm 0 0590 in Oil Ring Ring Groove Width 4 010 4 025 mm 0 1578 0 1584 in 4 130 mm 0 1625 in Ring Width 3...

Page 387: ...on Pin Bearing Inside Diameter 37 025 37 040 mm 1 4576 1 4582 in 37 100 mm 1 4606 in 5 44 Piston Pin Outside Diameter 36 994 37 000 mm 1 4564 1 4566 in 36 964 mm 2 4552 in Clearance 0 025 0 046 mm 0 0009 0 0018 in 0 110 mm 0 0043 in Inspection Item Standard Limit Reference Page Tappet Guide Hole Inside Diameter 14 249 14 270 mm 0 5609 0 5618 in 14 30 mm 0 5629 in 5 50 Tappet Stem Outside Diameter ...

Page 388: ... 159 174 lb ft 6 Timer Housing Bolt M8 x 1 25 No oil 33 3 37 3N m 3 4 3 8 kgf m 25 27 lb ft 7 Timer Gear Bolt M8 x 1 25 Coat with oil 34 8 38 8 N m 3 5 4 0 kgf m 26 29 lb ft 8 Idler Gear Shaft Bolt M10 x 1 5 Coat with oil 62 66 N m 6 3 6 7 kgf m 46 49 lb ft 9 Oil Pump Bolt M12 x 1 75 Coat with oil 98 118 N m 10 0 12 0 kgf m 72 87 lb ft 10 Turbocharger V Band Bolt 1 4 28 UNF Coat with Moly Coat on ...

Page 389: ...lue at left for 4T bolts and locknuts M8 x 1 25 22 5 28 5 N m 2 3 2 9 kgf m 17 21 lb ft M10 x 1 5 44 54 N m 4 5 5 5 kgf m 32 40 lb ft M12 x 1 75 78 2 98 2 N m 8 0 10 0 kgf m 58 72 lb ft PT Plug 1 8 9 8 N m 1 0 kgf m 7 0 lb ft 1 4 19 6 N m 2 0 kgf m 14 lb ft 3 8 29 4 N m 3 0 kgf m 22 lb ft 1 2 58 8 N m 6 0 kgf m 43 lb ft Pipe Joint Bolt M8 12 7 16 7 N m 1 3 1 7 kgf m 9 0 12 lb ft M10 19 5 25 5 N m ...

Page 390: ...SERVICE STANDARDS Tightening Torque for Bolts and Nuts 14 12 6LY3 Service Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

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