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PERIODIC MAINTENANCE

104

6LY3 Operation Manual

Perform the following maintenance every
250 hours or one year of operation,
whichever comes first.

• Check Fuel Injector Spray Pattern

• Adjust Intake / Exhaust Valve

Clearance (1st Time)

• Drain the Fuel Tank

• Replace the Fuel Filter Element

• Replace the Engine Oil (Crankcase)

• Replace the Engine Oil Filter Element

• Check the Seawater Pump Impeller

• Replace the Anode

• Clean the Air Intake Silencer

• Clean the Exhaust / Water Mixing

Elbow

• Clean the Turbocharger Blower

• Flush the Aftercooler

• Check the Wiring Connectors

• Tighten All Major Nuts and Bolts

• Check or Replace the Flexible Engine

Mounts

• Replace Engine Coolant

Check the Fuel Injector Spray
Pattern

Inspection and adjustment are necessary
to obtain optimal fuel injection to ensure
the best possible engine performance.
This inspection requires specialized
knowledge and techniques. See your
authorized Yanmar marine dealer or
distributor to check the injection spray
condition.

Adjust Intake / Exhaust Valve
Clearance (1st Time)

Inspection and adjustment must be made
to correct opening / closing timing lags of
the intake / exhaust valves which might
arise due to initial parts wear. This
inspection requires specialized knowledge
and techniques. See your authorized
Yanmar marine dealer or distributor to
adjust the intake / exhaust valve clearance.

Every 250 Hours of Operation

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Summary of Contents for 6LY3 series

Page 1: ...6LY3 series OPERATION MANUAL 6LY3 Operation Manual P N 0A1957 G0000 MARINE ENGINES Back ...

Page 2: ... Yanmar Co Ltd in Japan the United States and or other countries All Rights Reserved No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Yanmar Marine International 2005 Yanmar Marine International Back ...

Page 3: ...perate the machine to ensure that you follow safe operating practices and maintenance procedures Keep this Operation Manual in a convenient place for easy access If this Operation Manual is lost or damaged order a new one from your authorized Yanmar marine dealer or distributor Make sure this manual is transferred to subsequent owners This manual should be considered a permanent part of the engine...

Page 4: ... Engine Model __________________________________________________________ Engine Serial No _______________________________________________________ Date Purchased _________________________________________________________ Dealer _________________________________________________________________ Dealer Phone ___________________________________________________________ Back ...

Page 5: ...eration and Maintenance 3 Product Overview 21 Yanmar 6LY3 Features and Applications 21 Component Identification 22 Operation Side 22 Non Operation Side 23 Location of Labels 24 Nameplate 25 Function of Major Components 26 Electronic Control System ECS 27 Display 28 Before You Operate 35 Diesel Fuel 40 Diesel Fuel Specifications 40 Filling the Fuel Tank 41 Bleeding the Fuel System 43 Back ...

Page 6: ...ne Operation 53 Starting the Engine 64 Before Starting the Engine 64 To Start the Engine 64 Shifting 66 Cautions During Operation 67 Shutting Down the Engine 70 Normal Shutdown 70 Emergency Shutdown 70 Periodic Maintenance 73 Safety Precautions 73 Before You Operate 73 During Operation and Maintenance 74 Precautions 90 The Importance of Periodic Maintenance 90 Performing Periodic Maintenance 91 Th...

Page 7: ... Check the Fuel Injector Spray Pattern 104 Adjust Intake Exhaust Valve Clearance 1st Time 104 Drain the Fuel Tank 105 Replace the Fuel Filter Element 106 Replace the Engine Oil Crankcase 106 Replace the Engine Oil Filter Element 106 Check the Seawater Pump Impeller 106 Replace the Anode 107 Clean the Air Intake Silencer 107 Clean the Exhaust Water Mixing Elbow 108 Clean the Turbocharger Blower 108...

Page 8: ...k Fuel Feed Pump 111 Clean Engine Oil Cooler 111 Clean Seawater and Engine Coolant System 111 Replace Rubber Fuel Hoses 111 EPA Requirements 112 EPA Certification Plates 112 Conditions to Ensure Compliance with EPA Emission Standards 112 Inspection and Maintenance 113 Troubleshooting 115 Troubleshooting Chart 116 Troubleshooting Information 117 Long Term Storage 119 Before You Place the Engine in ...

Page 9: ...t make sure you order the new part and label at the same time A m This safety alert symbol appears with most safety statements It means attention become alert your safety is involved Please read and abide by the message that follows the safety alert symbol A DANGER Danger the word DANGER is in white letters with a red rectangle behind it indicates an imminently hazardous situation which if not avo...

Page 10: ...can cause damage to the engine personal property and or the environment or cause the engine to operate improperly 0000001enMarine CAUTION NEVER permit anyone to install or operate the engine without proper training Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures Safety signs and labels ...

Page 11: ...e the fill cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the fill cap Securely tighten the fill cap after you check the heat exchanger Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of engine coolant by observing the reserve tank Failure to comply will re...

Page 12: ...in death or serious injury 0000004en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette s...

Page 13: ...lt in death or serious injury 0000007en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become ...

Page 14: ...the air vent valve while the fuel system is being primed The fuel filter has an internal air bleed port Failure to comply will result in death or serious injury 0000016en A DANGER CRUSH HAZARD When you need to transport an engine for repair have a helper assist you attach it to a hoist and load it on a truck NEVER stand under hoisted engine If the hoist mechanism fails the engine will fall on you ...

Page 15: ...ne is operating Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002enMarine A WARNING EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vents or oth...

Page 16: ... work shoes eye and hearing protection as required by the task at hand NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing when you are working near moving rotating parts such as the flywheel or PTO shaft ALWAYS tie back long hair when you are working near moving rotating parts such as a flywheel or PTO shaft NEVER operate the engine while wearing a headset to listen to music or rad...

Page 17: ...kin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury 0000007en A WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious inj...

Page 18: ... service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine while it is operating remove all jewelry tie back long hair and keep your hands other body parts and clothing away from moving rotating parts Failure to comply could re...

Page 19: ...on and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000015en A WARNING FIRE HAZARD Undersized wiring systems can cause an electrical fire Failure to comply could result in death or serious injury 0000027en A CAUTION COOLANT HAZARD Wear eye protection and ...

Page 20: ...l system causing it to clog 0000004enMarine CAUTION If any problem is noted during the visual check the necessary corrective action should be taken before you operate the engine 0000021en CAUTION Be sure to close the seacock Neglecting to close the seacock could allow water to leak into the boat and may cause it to sink 0000152en CAUTION The illustrations and descriptions of optional equipment in ...

Page 21: ...l overheat 0000007en CAUTION Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear NEVER run the engine if the ambient temperature is above 40 C 104 F or below 16 C 5 F If the ambient temperature exceeds 40 C 104 F the engine may overheat and cause the engine oil to break down If the ambient temperature falls below 16 C 5 F rubber c...

Page 22: ...il Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of engine oil This may adversely affect the lubricating properties of the engine oil NEVER overfill Overfilling may result in white exhaust smoke engine overspeed or internal damage 0000005en CAUTION NEVER overfill the engine with engine oil ALWAYS keep the oil level between upper a...

Page 23: ... parts of the cooling system when the ambient temperature is below 0 C 32 F 0000154en CAUTION New Engine Break In On the initial engine start up check for proper engine oil pressure diesel fuel leaks engine oil leaks coolant leaks and for proper operation of the indicators and or gauges During the first 50 hours of operation operate your new engine under a substantial load at all times For best br...

Page 24: ... pressure water to clean the engine 0000014en CAUTION If the alarm window with audible alarm fails to display and go out about three seconds later when the rocker switch is pushed to the ON position see your authorized Yanmar marine dealer or distributor for service before operating the engine 0000028enMarine CAUTION NEVER use the Emergency Stop switch for a normal engine shutdown Use this switch ...

Page 25: ...cleaner element more frequently NEVER operate the engine with the air cleaner or element s removed This may allow foreign material to enter the engine and damage it 0000026en CAUTION Clean or replace the air cleaner element if the air intake restriction exceeds the value listed in the Operation and Service Manuals 0000046enMarine CAUTION NEVER turn off the battery switch if equipped or short the b...

Page 26: ...t of the throttle does not increase engine RPM you are overloading the engine that is running Immediately throttle back to approximately 2 3 throttle or to a setting where the engine performs normally Failure to do so may cause the running engine to overheat or cause excess carbon buildup which may shorten the engine s life 0000150en CAUTION If you have an installation with two or three engines an...

Page 27: ...e engine is operating the water pickup thru hull of the non running engine s should be closed This will prevent water from being forced past the seawater pump and eventually finding its way into the engine The result of water entering the engine could cause seizure or other serious problems 0000158en Back ...

Page 28: ...SAFETY 20 6LY3 Operation Manual This Page Intentionally Left Blank Back ...

Page 29: ... The engine must be installed correctly with the seawater or cooling water piping exhaust gas piping and electrical wiring Any auxiliary equipment attached to the engine should be easy to use and accessible for service To handle the drive equipment propulsion systems including the propeller and other onboard equipment be sure to observe the instructions and cautions given in the operation manuals ...

Page 30: ...FICATION Operation Side Figure 1 1 3 4 5 6 7 8 9 10 0002020 2 1 Oil Fill Cap 2 Coolant Fill Cap 3 Electronic Control Unit Cover Plate 4 Fuel Injection Pump 5 Lube Oil Cooler 6 Lube Oil Filter 7 Inter Cooler 8 Flywheel 9 Air Intake Silencer 10 Turbocharger Back ...

Page 31: ... 6LY3 Operation Manual 23 Non Operation Side Figure 2 0002021 4 1 3 5 2 6 7 8 1 Coolant Tank Exhaust Manifold 2 Dipstick 3 Fresh Water Cooler 4 Seawater Pump 5 Alternator 6 V Belt 7 Fuel Filter 8 Fresh Water Pump Back ...

Page 32: ...Y3 series engines Please replace if damaged or lost Figure 3 128296 07300 120324 07240 128296 07260 128296 07350 Warning Labels No Description Part Number 1 Hot Surface 128296 07300 2 Lifting Precautions 120324 07240 3 Engine Coolant Fill Cap 128296 07260 4 Rotating Parts 128296 07350 5 Fall Hazard 119578 07890 0002079 5 1 2 3 4 Back ...

Page 33: ...e 4 is attached to the engine Check the engine model output rpm and serial number on the nameplate Figure 4 DO NOT STEP ON COVERS POSSIBILITY OF A FALL YANMAR DIESEL ENGINE YANMAR CO LTD MADE IN JAPAN MODEL CONT RATING Kw SPEED OF PROP SHAFT MAX OUT PUT Kw ENGINE NO rpm rpm rpm 0002019 Back ...

Page 34: ...has a pressure regulating valve When the cooling water temperature rises the pressure rises inside the fresh water system Coolant Recovery Tank The pressure regulating valve releases vapor and hot water overflow to the coolant recovery tank When the engine stops and the cooling water cools the pressure in the cooling water tank also drops very low The fill cap valve then opens to send water back f...

Page 35: ...Yanmar Electronic Control System Operation Manual for LY3 Engines for a more complete description of the electronic control system ECS Figure 5 Start Eng ON OFF Emergency Stop Sub throttle active Sub throttle Model i2 Module 0002022 3 4 1 2 8 5 7 6 9 1 First Station Rocker Switch Panel 2 To Engine 3 Interface Module without Trolling Interface Module with Trolling Optional 4 To Engine 5 To Marine G...

Page 36: ...ics Figure 7 Alarm Log Screen Figure 8 Figure 8 Alarm Indicator Functions Alarm indicators and buzzer come on when sensors detect an abnormality during engine operation The alarm indicators are off during normal operation but come on as follows when an abnormality arises Cooling water temperature alarm indicator comes on when the fresh water gets too hot Lube oil pressure alarm indicator comes on ...

Page 37: ...ne after using the EMERGENCY STOP switch may be slower or more difficult than normal starting 3 Sub Throttle Control Figure 9 3 In the unlikely event that the throttle control fails the sub throttle indicator light will flash and the engine speed is controlled the sub throttle Engine speed rises when the sub throttle knob is turned clockwise When the sub throttle indicator flashes turn the sub thr...

Page 38: ... If the associated control head lever is in the Neutral Idle position pushing this button engages disengages Neutral Throttle control allowing throttle but no forward or reverse thrust If the associated control head lever is in a Gear Idle position pushing this button engages disengages Split Range Throttle SRT if installed SELECT or SEL Button If the station is inactive pushing this button activa...

Page 39: ...Engaging Disengaging Shift Disconnect Mode Figure 14 Engage a Return the handle s to neutral The neutral light s glow steady Figure 14 1 b Press the NEUTRAL button s Figure 14 2 The neutral light s flash star around light s in Figure 14 2 c Move the handle s to forward or reverse throttle Figure 14 3 resulting in engine rpm control without engaging marine gear Disengage a Return the handle s to ne...

Page 40: ...ever on the control head The N Neutral lamp Figure 15 2 will flash to indicate that the Split Range Throttle is engaged b While in the Split Range Throttle the system will shift normally but the throttle will be limited in both gears c If the system is shifted into neutral while in the Split Range Throttle engine mode the N Neutral lamp will come on steady to indicate that the system is in neutral...

Page 41: ... button Figure 16 2 on the control head The sync lamp flashes if the handles are not within 10 of each other Figure 16 3 The sync lamp will stop flashing and remain continuously lit Figure 16 4 when the levers are moved to within this 10 range A steady sync lamp confirms that the Cruise Sync is engaged While the engines are synchronized all engine speeds are matched any time the control levers are...

Page 42: ...PRODUCT OVERVIEW 34 6LY3 Operation Manual This Page Intentionally Left Blank Back ...

Page 43: ...t CAUTION NEVER permit anyone to install or operate the engine without proper training Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures Safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized Yanmar marine dealer or distributor f...

Page 44: ...in death or serious injury 0000002en6LY3 A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigaret...

Page 45: ... diesel fuel or other flammable material such as oil hay or dried grass close to the engine during engine operation or shortly after shut down Failure to comply will result in death or serious injury 0000014en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions When you prime the fuel system operate the fuel priming lever of the mechanical f...

Page 46: ...he damage Failure to comply could result in death or serious injury 0000008enMarine A WARNING BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011en A WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces ...

Page 47: ... engine performance to prevent engine damage and to comply with EPA warranty requirements Only use clean diesel fuel NEVER remove primary strainer from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog 0000004enMarine CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seiz...

Page 48: ...thorized Yanmar marine dealer or distributor for more information Ash content not to exceed 0 01 by volume Carbon residue content not to exceed 0 35 by volume Less than 0 1 is preferred Total aromatics content should not exceed 35 by volume Less than 30 is preferred PAH polycyclic aromatic hydrocarbons content should be below 10 by volume CAUTION Only use the engine coolant specified Other engine ...

Page 49: ...in 8 Fuel Shutoff Valve 9 Less Than 500 mm 19 68 in 10 To Fuel Injection Pump 0002050 1 4 5 7 8 9 10 2 3 6 A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately K...

Page 50: ...0000014en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after two years or 200...

Page 51: ... Loosen the air bleed screw at the top of the fuel water separator 2 3 turns When fuel with no air bubbles flows freely tighten the air bleed screw 2 Loosen the air bleed screw of the fuel filter 2 3 turns 3 Move the knob on top of feed pump several times to feed fuel Continue to move feed pump knob until fuel with no air bubbles flows freely 4 Tighten the air bleed screw IMPORTANT NEVER use the s...

Page 52: ...being operated See the SAE Service Grade Viscosity Chart Figure 2 4 Yanmar does not recommend the use of engine oil additives Figure 2 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 CAUTION Only use the engine oil specified Other engine oils may affect war...

Page 53: ...3 5 lines on the dipstick 5 Fully reinsert dipstick Figure 3 Adding Engine Oil 1 Remove the yellow filler port cap Figure 3 2 at the top of the rocker arm cover Figure 3 1 and fill with engine oil 2 Fill with oil to the upper limit Figure 3 4 on the dipstick Figure 3 3 Insert the dipstick fully to check the level Full Figure 3 4 means the oil amount at the upper limit on a dipstick Effective means...

Page 54: ...en6LY3 A CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle Long Life or Extended Life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an inte...

Page 55: ...se the proper amount of coolant concentrate for the ambient temperature as specified by the LLC manufacturer LLC concentration should be a minimum of 30 to a maximum of 60 Too much LLC will decrease the cooling efficiency also Do not mix different types or brands of LLC or a harmful sludge may form Do not use hard water Water should be clean and free from sludge or particles Following the manufact...

Page 56: ...m the production plant Figure 4 A DANGER SCALD HAZARD NEVER remove the fill cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the fill cap Securely tighten the fill cap after you check the heat exchanger Steam can spurt out during engine operation if the cap is loose ALWAYS check the level of engin...

Page 57: ...he coolant recovery tank cap Figure 7 2 and fill with coolant mix to the lower limit Figure 7 4 Replace cap Never fill to the upper limit Figure 7 3 Coolant recovery tank capacity 0 8 L 1 7 pints 6 Check the rubber hose Figure 7 1 connecting the coolant recovery tank to the heat exchanger Be sure the hose is securely connected and there is no looseness or damage If leaks develop in the hose or at ...

Page 58: ...witch to the ON position 7 Push and hold the start switch for 15 seconds cranking Release the start switch and the engine stops Wait for 15 seconds and repeat again for 15 seconds This will distribute oil to the lubricated parts 8 Push the SELECT button then push the N button and the N lamp flashes Push the start switch to start the engine Release the switch when the engine has started Raise the e...

Page 59: ...have to drain the fuel filter water separator frequently drain the fuel tank and check for the presence of water in your fuel supply See Drain the Fuel Tank on page 105 A WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you...

Page 60: ...o operate see your authorized Yanmar dealer or distributor Checking the Alarm Indicators When operating the start switch on the rocker switch panel check that there is no alarm message on the display and the alarm indicators work normally See Display Function on page 28 Preparing Fuel Oil and Coolant in Reserve Prepare sufficient fuel for the day s operation Always store engine oil and coolant in ...

Page 61: ...NEVER permit anyone to install or operate the engine without proper training Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures Safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized Yanmar marine dealer or distributor for additio...

Page 62: ...engine operation if the cap is loose ALWAYS check the level of engine coolant by observing the reserve tank Failure to comply will result in death or serious injury 0000002en6LY3 A DANGER EXPLOSION HAZARD Keep the area around the battery well ventilated While the engine is running or the battery is charging hydrogen gas is produced which can be easily ignited Keep sparks open flame and any other f...

Page 63: ...n flames or any other form of ignition match cigarette static electric source well away when refueling NEVER overfill the fuel tank Fill the fuel tank Store any containers containing fuel in a well ventilated area away from any combustibles or sources of ignition Failure to comply will result in death or serious injury 0000005en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explo...

Page 64: ...t down Failure to comply will result in death or serious injury 0000014en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines ten...

Page 65: ...e engine is operating Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002enMarine A WARNING EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vents ...

Page 66: ...gloves work shoes eye and hearing protection as required by the task at hand NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing when you are working near moving rotating parts such as the flywheel or PTO shaft ALWAYS tie back long hair when you are working near moving rotating parts such as a flywheel or PTO shaft NEVER operate the engine while wearing a headset to listen to music ...

Page 67: ...AZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011en A WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shor...

Page 68: ...ed by Yanmar for the best engine performance to prevent engine damage and to comply with EPA warranty requirements Only use clean diesel fuel NEVER remove primary strainer from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog 0000004enMarine CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal ...

Page 69: ... affect the properties of the engine coolant 0000006enTrans CAUTION The illustrations and descriptions of optional equipment in this manual such as the operator s console are for a typical engine installation Refer to the documentation supplied by the optional equipment manufacturer for specific operation and maintenance instructions 0000018en CAUTION If any problem is noted during the visual chec...

Page 70: ...ain engine performance and avoid premature engine wear NEVER run the engine if the ambient temperature is above 40 C 104 F or below 16 C 5 F If the ambient temperature exceeds 40 C 104 F the engine may overheat and cause the engine oil to break down If the ambient temperature falls below 16 C 5 F rubber components such as gaskets and seals will harden causing premature engine wear and damage See y...

Page 71: ...ne is operating it is important to limit the amount of throttle applied to the running engine If you observe black smoke or movement of the throttle does not increase engine RPM you are overloading the engine that is running Immediately throttle back to approximately 2 3 throttle or to a setting where the engine performs normally Failure to do so may cause the running engine to overheat or cause e...

Page 72: ...d the following changes occur Figure 3 The needle appears in the engine tachometer on the display Figure 4 To Start the Engine To start the engine press START upper half of ENG ON switch Figure 3 1 If the Engine Fails to Start 0002056 2 1 TE i5501E Multi Function Display Electronic Controls V1 0 Copyright Teleflex Inc 0002057 CAUTION NEVER hold the key in the START position for longer than 15 seco...

Page 73: ...engine 5 Check that sufficient seawater is discharged from the seawater outlet pipe Operation with inadequate seawater discharge will damage the impeller of the seawater pump If seawater discharge is too small stop the engine immediately Identify the cause and repair Is the seacock open Is the inlet of the seacock on the hull bottom clogged Is the seawater suction hose broken or does the hose suck...

Page 74: ...igure 5 Ahead Gradually move the control lever in the F forward direction Figure 5 2 to the position of the Forward Detent The marine gear will shift into FORWARD The engine will remain at idle Pushing further on the control lever will increase the rpm up to a maximum of wide open throttle WOT Astern Gradually move the control lever in the R reverse direction to the position of the Reverse Detent ...

Page 75: ...ne engine is operating the water pickup thru hull of the non running engine s should be closed This will prevent water from being forced past the seawater pump and eventually finding its way into the engine The result of water entering the engine could cause seizure or other serious problems 0000158en CAUTION If you have an installation with two or three engines and only one engine is operating it...

Page 76: ...ly become great at a certain engine speed range causing heavy vibrations Avoid operation in this speed range If you hear any abnormal sounds stop the engine and inspect CAUTION New Engine Break In On the initial engine start up check for proper engine oil pressure diesel fuel leaks engine oil leaks coolant leaks and for proper operation of the indicators and or gauges During the first 50 hours of ...

Page 77: ...This is done to clean out carbon from the cylinders and the fuel injection valve Neglecting to race the engine will result in poor exhaust color and reduce engine performance 8 If possible periodically operate the engine at near maximum rpm while underway This will generate higher exhaust temperatures which will help clean out hard carbon deposits maintaining engine performance and prolonging the ...

Page 78: ...ight of the panel and the engine shuts down immediately without the time lag of regular engine shutdown After shutdown push the bottom part of the emergency stop switch Figure 6 2 to be returned to the former position CAUTION For maximum engine life Yanmar recommends that when shutting the engine down you allow the engine to idle without load for 5 minutes This will allow the engine components tha...

Page 79: ... the ON switch on the panel check that the trouble indication does not appear in the display normal condition Figure 7 1 0002063 2 A WARNING SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the...

Page 80: ...ENGINE OPERATION 72 6LY3 Operation Manual This Page Intentionally Left Blank Back ...

Page 81: ... permit anyone to install or operate the engine without proper training Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures Safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized Yanmar marine dealer or distributor for additional t...

Page 82: ...is charging Failure to comply will result in death or serious injury 0000003en A DANGER SCALD HAZARD NEVER remove the fill cap if the engine is hot Steam and hot engine coolant will spurt out and seriously burn you Allow the engine to cool down before you attempt to remove the fill cap Securely tighten the fill cap after you check the heat exchanger Steam can spurt out during engine operation if t...

Page 83: ...tely Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER use diesel fuel as a cleaning agent Failure to comply will result in death or serious injury 0000012en...

Page 84: ...explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric source well away when refueling NEVER overfill the fuel tank Fill the fuel tank Store ...

Page 85: ...ath or serious injury 0000015en A DANGER EXPLOSION HAZARD NEVER check the remaining battery charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use a hydrometer to check the remaining battery charge If the electrolyte is frozen slowly warm the battery before you recharge it Failure to comply will result in death or serious injury 0000007en A DANGER C...

Page 86: ...o comply will result in death or serious injury 0000010en A WARNING SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the engine NEVER start the engine in gear Sudden movement of the engine and ...

Page 87: ...gines create carbon monoxide gas during operation Accumulation of this gas within an enclosure could cause illness or even death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injury 0000003en A WARNING ALCOHOL AND DRUG HAZARD NEVER operate the engine while you are under the influence of a...

Page 88: ...he warning signals Failure to comply could result in death or serious injury 0000005enMarine A WARNING SUDDEN MOVEMENT HAZARD Be sure the boat is in open water away from other boats docks and other obstructions before increasing rpm Failure to comply could result in death or serious injury 0000006enMarine A WARNING BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in co...

Page 89: ... a fuel leak with your hands ALWAYS use a piece of wood or cardboard Have your authorized Yanmar marine dealer or distributor repair the damage Failure to comply could result in death or serious injury 0000008enMarine A WARNING SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for crac...

Page 90: ... comply could result in death or serious injury 0000010en A WARNING BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en A WARNING BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear e...

Page 91: ...ystems can cause an electrical fire Failure to comply could result in death or serious injury 0000027en A CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle Long Life or Extended Life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005en A CAUTION FLY...

Page 92: ...in this manual such as the operator s console are for a typical engine installation Refer to the documentation supplied by the optional equipment manufacturer for specific operation and maintenance instructions 0000018en CAUTION If any indicator illuminates during engine operation stop the engine immediately Determine the cause and repair the problem before you continue to operate the engine 00000...

Page 93: ...st gases that exceed the design specifications 0000065enMarine CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating engine coolant Carefully clean the heat exchanger cap and the surrounding area before you remove the cap NEVER mix different t...

Page 94: ... engine is installed on a level surface If a Yanmar Marine Engine is installed at an angle that exceeds the specifications stated in the Yanmar Marine Engine Operation Manual engine oil may enter the combustion chamber causing excessive engine speed white exhaust smoke and serious engine damage This applies to engines that run continuously or those that run for short periods of time 0000010enMarin...

Page 95: ...or high pressure water to clean the engine 0000014en CAUTION If the alarm window with audible alarm fails to display and go out about three seconds later when the rocker switch is pushed to the ON position see your authorized Yanmar marine dealer or distributor for service before operating the engine 0000028enMarine CAUTION NEVER use the Emergency Stop switch for a normal engine shutdown Use this ...

Page 96: ...he air cleaner element more frequently NEVER operate the engine with the air cleaner or element s removed This may allow foreign material to enter the engine and damage it 0000026en CAUTION Clean or replace the air cleaner element if the air intake restriction exceeds the value listed in the Operation and Service Manuals 0000046enMarine CAUTION NEVER turn off the battery switch if equipped or shor...

Page 97: ...movement of the throttle does not increase engine RPM you are overloading the engine that is running Immediately throttle back to approximately 2 3 throttle or to a setting where the engine performs normally Failure to do so may cause the running engine to overheat or cause excess carbon buildup which may shorten the engine s life 0000150en CAUTION If you have an installation with two or three eng...

Page 98: ...ted downtime reduces the number of accidents due to poor machine performance and helps extend the life of the engine CAUTION If you have an installation with two or three engines and only one engine is operating the water pickup thru hull of the non running engine s should be closed This will prevent water from being forced past the seawater pump and eventually finding its way into the engine The ...

Page 99: ...horten the life of the engine Yanmar Replacement Parts Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed Genuine replacement parts help ensure long engine life Tools Required Before you start any periodic maintenance procedure make sure you have the tools you need to perform all of the required tasks Ask Your Authorized Yanmar Marine Dealer for Help Our professi...

Page 100: ...n page 112 for operating conditions Tightening Fasteners Use the correct amount of torque when you tighten fasteners on the machine Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure STANDARD TORQUE CHART CAUTION The tightening torque in the Standard Torque Chart should be applied only to the bolts with a 7 head JIS strength c...

Page 101: ...urs and thereafter require special knowledge and techniques Consult your Yanmar dealer or distributor Refer to the separate manual of marine gear for the periodical inspection c Check Replace z Contact your authorized Yanmar marine dealer or distributor System Item Daily Periodic Maintenance Interval Every 50 hrs or onemonth whichever comes first Every 250 hrs or one year whichever comes first Eve...

Page 102: ...z Electrical System Check the alarm indicators c Check the electrolyte level in the battery c Adjust replace the tension of the alternator belt c c Check the wiring connectors c Engine Cylinder Head and Block Check for leakage of fuel engine oil and engine coolant c After starting Tighten all major nuts and bolts z Adjust intake exhaust valve clearance z 1st time z Miscellaneous Items Check the el...

Page 103: ...nance items shown above to be performed at your Yanmar dealer or distributor Parts Interval Clean fuel injection nozzle 1500 hours Check fuel injection nozzle adjustment 3000 hours Check fuel injection pump adjustment Check turbocharger adjustment Check electronic engine control unit ECU and its associated sensors and actuators Back ...

Page 104: ...m After Initial 50 Hours of Operation A WARNING BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011en CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize or s...

Page 105: ...e oil See Adding Engine Oil on page 45 6 Perform a trial run and check for oil leaks 7 Approximately 10 minutes after stopping the engine remove the oil dipstick and check the oil level Add oil if the level is too low CAUTION 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...

Page 106: ...se or corroded connectors Check the Electronic Control System Operation The electric governor on the engine and the marine gear are connected to the control head rocker switch panel and display through electric devices such as the Engine Interface Module Adjust the Propeller Shaft Alignment The flexible engine mounts are compressed a little in the initial engine operation which may cause centering...

Page 107: ...NGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The f...

Page 108: ...el in the fuel tank water may not drip out when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out 0000025en CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agenc...

Page 109: ...ark and may cause an explosion or fire Use a hydrometer to check the remaining battery charge If the electrolyte is frozen slowly warm the battery before you recharge it Failure to comply will result in death or serious injury 0000007en A WARNING BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in contact with clothing skin or eyes Severe burns could result ALWAYS wear...

Page 110: ...ravity of below 1 24 needs charging If the specific gravity cannot be raised by charging the battery must be replaced Note The capacities of the standard alternator and the recommended battery assume only the power necessary for regular operation If the power is also used for inboard lighting or other purposes the generating and charging capacities may be insufficient In such cases see your author...

Page 111: ...igure 5 3 to adjust the V belt tension 3 If the V belt is damaged or worn replace it Loosen the adjuster bolt Figure 5 2 and move the alternator Figure 5 3 Remove belt from pulleys 4 Install new belt per routing Figure 5 and adjust the tension as shown in Step 2 A WARNING SEVER HAZARD Stop the engine before you begin to service it ALWAYS turn off the battery switch when you are servicing the engin...

Page 112: ...s Check or Replace the Flexible Engine Mounts Replace Engine Coolant Check the Fuel Injector Spray Pattern Inspection and adjustment are necessary to obtain optimal fuel injection to ensure the best possible engine performance This inspection requires specialized knowledge and techniques See your authorized Yanmar marine dealer or distributor to check the injection spray condition Adjust Intake Ex...

Page 113: ...fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009en CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other g...

Page 114: ...6 Check the Seawater Pump Impeller Depending on use the inside parts of the seawater pump deteriorate and discharge performance drops At the specified interval or when the volume of seawater discharged is reduced inspect the seawater pump in accordance with the following procedures 1 Loosen the side cover bolts and remove the side cover 2 Illuminate the inside of the seawater pump with a flashligh...

Page 115: ... the impeller and damage it Figure 7 Replace the Anode The timing for replacing anode varies depending on the characteristics of the seawater and operational conditions Inspect the anode periodically and remove the corroded area on the surface Replace the anode when it has decreased to less than 1 2 of the original volume If replacement of anode is neglected and operation is continued with a corro...

Page 116: ...nd clean the aftercooler This should be done only by a trained and qualified technician See your authorized Yanmar marine dealer or distributor to flush the aftercooler Check the Wiring Connectors Check for any loose connections Tighten All Major Nuts and Bolts After long period of usage the major nuts and bolts of the engine may loosen Tighten the major nuts and bolts to the standard tightening t...

Page 117: ...st Replace Seawater Pump Impeller Adjust the Propeller Shaft Alignment Check Alternator Belt Tension Replace the Seawater Pump Impeller Replace the used seawater pump impeller periodically See your authorized Yanmar marine dealer or distributor Adjust the Propeller Shaft Alignment The rubber tension of the flexible engine mounts is lost after many hours use This leads to a drop in vibration absorp...

Page 118: ...ce requires specialized knowledge See your authorized Yanmar marine dealer or distributor to clean and check the water passages Replace Alternator Belt Replace the alternator belt with a new one every 1000 hours or four years whichever comes first even if there is no crack or damage in the surface See Adjust Alternator V Belt Tension on page 103 Adjust Intake Exhaust Valve Clearance Proper adjustm...

Page 119: ...clean and maintain the engine oil cooler See your authorized Yanmar marine dealer or distributor to clean the engine oil cooler Clean Seawater and Engine Coolant System Rust and scale are deposited inside the seawater and engine coolant system during long use This lowers cooling performance so it is necessary to clean and maintain the following parts in addition to replacing the coolant Relevant C...

Page 120: ... as follows 1 Ambient temperature 20 40 C 4 104 F 2 Relative humidity 80 or lower 3 Permissible value for intake negative pressure 3 9 kPa 400 mmAq or lower 4 Permissible value for exhaust back pressure 19 6 kPa 2000 mmAq or lower The fuel and lubricating oil used should be as follows Diesel fuel oil ASTM D975 No 1 D or No 2 D or equivalent minimum of cetane No 45 Lubricating Oil Type API Class CD...

Page 121: ... the Inspection and Maintenance of EPA Emission Related Parts section are covered in Periodic Maintenance Schedule on page 93 This maintenance must be performed to keep the emission values of your engine in the standard values during the warranty period The warranty period is determined by the age of the engine or the number of hours of operation See Yanmar Co Ltd Limited Emission Control System W...

Page 122: ...PERIODIC MAINTENANCE 114 6LY3 Operation Manual This Page Intentionally Left Blank Back ...

Page 123: ... to display and go out about three seconds later when the rocker switch is pushed to the ON position see your authorized Yanmar marine dealer or distributor for service before operating the engine 0000028enMarine CAUTION If any alarm indicator with audible alarm sound appears on the display during engine operation stop the engine immediately Determine the cause and repair the problem before you co...

Page 124: ...g system See your authorized Yanmar marine dealer or distributor Faulty Warning Devices Do not operate the engine if alarm devices are not repaired Serious accidents may result if difficulties are not spotted due to faulty alarm lamps 1 When switch is turned ON Alarm buzzer sounds Circuit broken Note Alarm buzzer only sounds when there is an abnormality See your authorized Yanmar marine dealer or ...

Page 125: ...ame and serial number of your engine Boat name hull material size tons Use type of boating number of hours run Total number of operation hours refer to hourmeter age of boat Operating conditions when the problem occurs Engine rpm Color of exhaust smoke Type of diesel fuel Type of engine oil Any abnormal noises or vibration Operating environment suchas high altitude or extreme ambient temperatures ...

Page 126: ...TROUBLESHOOTING 118 6LY3 Operation Manual This Page Intentionally Left Blank Back ...

Page 127: ...water from the cooling system A WARNING BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en CAUTION If seawater is left inside of the engine it may freeze and damage parts of the cooling system when the ambient temperature is below 0 C 32 F 0000154en Back ...

Page 128: ...uel or fill the tank completely to help prevent condensation inside the tank 3 Refill the heat exchanger with engine coolant See Filling Heat Exchanger with Engine Coolant on page 48 4 Cover the turbocharger exhaust pipe etc with vinyl sheets and seal them to prevent moisture from entering 5 Completely drain the bilge Put the boat in dry dock if possible 6 Waterproof the engine room to prevent rai...

Page 129: ...21 kW 295 kW 254 kW Fuel Stop Power Output at Crankshaft Engine Speed Note 1 and Note 2 3300 min rpm 480 hp Metric 440 hp Metric 380 hp Metric 353 kW 324 kW 279 kW at fuel inlet temp 40 C 104 F High Idling Note 3 3500 25 min rpm Low Idling Note 3 700 25 min rpm Installation Flexible mounting Direction of Rotation Crankshaft Counterclockwise viewed from stern Cooling System Liquid cooling with heat...

Page 130: ...els coolers and filter 6 The Effective Engine Lubricating Oil Capacity indicates the difference in maximum scale of the dipstick and minimum scale Starting System Type Electric Starting Motor DC 12V 3kW AC Generator 12V 80A Turbocharger Model RHC7W IHI made Type Water cooled Engine Dimension Overall Length 1300 4 mm 51 2 in Overall Width 801 3 mm 31 5 in Overall Height 776 6 mm 30 6 in Engine Dry ...

Page 131: ...ONLY YANMAR CO LTD LIMITED EMISSION CONTROL SYSTEM WARRANTY USA ONLY The following EPA Warranty only applies to engines built on or after January 01 2006 and labeled with the proper nameplate Figure 1 Figure 1 0003493 Back ...

Page 132: ...no charge to you for diagnosis parts and labor Warranty service or repair will be provided at authorized Yanmar marine deals or distributors It is recommended that any replacement parts used for maintenance repair or replacement of emission control systems are Yanmar parts The owner may elect to have maintenance replacement or repair of the emission control components and systems performed by any ...

Page 133: ...umable items made in connection with scheduled maintenance Owner s Responsibility As the Yanmar marine engine owner you are responsible for the performance of the required maintenance listed in your Operation Manual Yanmar recommends that you retain all documentation including receipts covering maintenance on your marine engine but Yanmar cannot deny warranty solely for the lack of receipts or for...

Page 134: ...President Yanmar Marine Int l Back ...

Page 135: ...President Yanmar Marine Int l Back ...

Page 136: ...EPA WARRANTY USA ONLY 126 This Page Intentionally Left Blank Back ...

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