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Wiring Diagram - 24 V (Optional)

ＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥ Ｅ

ＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥＥＥ

1

2

Ｅ

Ｅ

Ｅ

3

ＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥ.5Ｅ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

G10K/B(1.25)

B13D/WG(1.25)

P21/LB(0.5)

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

E80(CANH)%W(0.5)

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

E80A(CANH)%W(0.5)

B13E/WL(0.5)

G10J/B(0.5)

J:E8-A

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

Water T.

Fuel T.

Oil T.

Boost P.

Oil P.

J:JA4

11

37

28

39

40

27

35

29

24

22

14

33

34

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

5A

10A

ＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

G11C/BBr(0.5)

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

E51/YL(0.5)Throtle position

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

E61/LR(0.5)Actuator reray

G10A/B(1.25)GND

G10B/B(1.25)GND

ENG EARTH

G02/B(1.25)Shield GND

36

26

25

15

Timer solenoid/Retard

3

ＥＥＥＥＥＥＥＥＥＥ

2

ＥＥＥＥＥＥＥＥＥＥ

20

B21A/GR(0.5)Emergency Stop

4

E12/W(0.5)Air heater-A

5

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

8

E01A/W(1.25)Starter ON

21

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

10

B12A/G(0.5)2nd staition key

19

B11A/L(0.5)1st staition key

12

B20/LW(0.5)ECU main relay

30

E30/%W(0.5)Position sensor

ＥＥＥＥＥＥＥＥ

E10/R(8)

E11/RW(8)

B02/R(8)

B03/RW(8)

B01B/R(10)

B01A/R(20)

G10G/B(0.5)

G10F/B(0.5)

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥ.ＥＥ

Air heater relay B Normaly OPEN

B04/W(5)

B01C/R(5)

Starter relay Normaly OPEN

E02/W(1.25)

G10E/B(1.25)

E01/W(1.25)

E03/WO(0.5)

B13J/WR(0.5)

2nd station relay Normally open

1st station relay Normally open

ECU main relay Normally open

S

B01/R(8)

B13B/WR(1.25)

B12/G(0.5)

B07D/RW(1.25)

G10D/B(1.25)

B13A/WR(1.25)

B11/L(0.5)

B07C/RW(1.25)

G10D/B(1.25)

B13H/WR(1.25)

B13/WR(1.25)

B20/LW(0.5)

B07A/RW(1.25)

ENG EARTH

5A

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ENG EARTH

ＥＥＥＥＥＥＥＥＥＥＥ

ENG EARTH

1

E60/W(1.25)Actuator

Ｅ

E38/%L(0.5)/Cam pulse +

17

E37/%B(0.5)/pulse -

Ｅ

E36/%W(0.5)/pulse +

16

ＥＥＥ

20A

5A

Emergency Stop SW Normally close

Sub throttle indicator

Emergency throttle position sensor

ＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

Ｅ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

Ｅ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

Ｅ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

Ｅ

Shield

0.42-4.58V

E80(CANH)/%W(0.5)

B13/WR(1.25)+12V DC

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

P21A/LB(0.5)

P20A/RB(0.5)

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥ

Starter check relay Normally open

B06A

J:MW5

J:MW4

ＥＥＥ

G10C/B/(1.25)Power GND

G10A/B/(1.25) GND

G10B/B/(1.25) GND

10A

ＥＥＥ

J:ME1

ＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥ

Battery

+

-

24V GND

SLD4/B(0.5)

SLD1/B(0.5)

SLD3/B(0.5)

SLD2/B(0.5)

B13F

WR(1.25)

B13G

WR(1.25)

J:MW3

J:MW2

ＥＥＥＥＥＥＥＥＥＥＥ

B14/Gr(1.25)

E61/LR(0.5)

B21/GR(1.25)

B13N/WR(1.25)

Inj. pump actuator relay

Normally open

G11A/BBr(0.5)

ＥＥＥＥＥＥＥＥＥＥＥ

70A

50A

ＥＥＥＥ

ＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥ ＥＥＥ

ECU

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

J:MT1

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ.ＥＥ

ＥＥＥＥＥＥＥＥＥ.ＥＥ

ＥＥＥＥＥＥＥＥ.ＥＥ

ＥＥＥＥ

ＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥ

Timer advance

Timer retard

ＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥ

B07A

ＥＥＥＥＥＥＥＥ

B01E/R(8)

B01D/R(5)

ＥＥＥ

Ｅ

ＥＥＥＥＥＥＥＥＥＥ

ENG EARTH

ＥＥＥＥ

ＥＥＥＥＥＥＥＥ

ＥＥＥ

ＥＥＥ

ＥＥＥ

ＥＥＥＥＥＥＥＥ.ＥＥ

ＥＥＥＥＥＥＥＥ.ＥＥ

ＥＥＥＥＥＥ

ＥＥＥ

ＥＥＥ

Crank speed sensor

Fuel inj. pump

Sensor

Actuator

CAM

ＥＥＥＥＥＥＥ.ＥＥＥ

B14/Gr(1.25)

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥ

Ｅ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

1

2

Ｅ

Ｅ

3

Ｅ

ＥＥＥＥＥＥＥＥ

GND

5V

ＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

Service Tool

Ｅ

Ｅ

Ｅ

Ｅ

DEUTSCH DT06-12SA-CE05

DEUTSCH DT04-12PA-CE07

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

RW(1.25)

ＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥ

ＥＥ

9

8

1

3

11

4

10

5

12

2

6

7

ＥＥＥＥＥＥＥＥＥＥ

Timer solenoid/Advance

Emergency Stop SW Normally close

Ignition SW

Ignition SW

J:MW1

ＥＥＥＥＥ

J:ME4

ＥＥＥＥＥ

J:W-1

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ 
ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

J:MT2

J:MT3

J:JA1

B21A/GR(1.25)

ＥＥＥＥ

ＥＥＥＥ

G10C

J:MW6

Alternator

L

B

ＥＥＥ→ＥＥＥ

24V GND

ＥＥＥＥＥＥＥＥＥ

Ｅ

24V GND

G01/B(8)

ＥＥＥＥＥＥ

ＥＥＥＥＥＥ

ＥＥＥＥＥＥ

ENG EARTH

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥ

ＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥ

ＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

Ignition switch circuit

○

○

○

○

○

○

30

AC

17

G2

off

on

start

DEUTSCH DT06-12SA-CE05

DEUTSCH DT04-12PA-CE07

DEUTSCH DT06-12SA-CE05

DEUTSCH DT04-12PA-CE07

DEUTSCH DT06-12SA-CE05

DEUTSCH DT04-12PA-CE07

DEUTSCH DT06-6S-CE05

DEUTSCH DT04-6P-CE03

DEUTSCH DT06-6S-CE05

DEUTSCH DT04-6P-CE03

DEUTSCH

DT06-2S

NMEA

POWER

DEUTSCH

DT06-3S

ＥＥＥ

ＥＥＥＥＥ

DEUTSCH

DT06-12SA

ＥＥＥ

ＥＥＥＥＥＥ

B

Starter

17

30

G2

ＥＥ

17

30

G2

ＥＥ

LED

Mark

B:

R:

L:

W:

G:

Gr:

Y:

Br:

O:

Lg:

P:

Pr:

Color

Black

Red

Blue

White

Green

Gray

Yellow

Brown

Orange

Light Green

Pink

Purple

Ｅ

Ｅ

Ｅ

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

OEM Responsibilty

ＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥ

ＥＥＥＥＥＥＥ ＥＥＥ

TELEFLEX components

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

1

0006654

SPECIFICATIONS

74

6LY3 LDC Operation Manual

© 2008 Yanmar Marine International

Summary of Contents for 6LY3-STC

Page 1: ...MARINE ENGINE 6LY3 series OPERATION MANUAL 6LY3 STC 6LY3 UTC P N 0ALY3 G00200 ...

Page 2: ... product service or maintenance improvement We reserve the right to make any change at any time without notice Yanmar and are registered trademarks of Yanmar Co Ltd in Japan the United States and or other countries All Rights Reserved No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical including photocopying recording taping or informatio...

Page 3: ...cation 11 Service Side 11 Non Service Side 12 Nameplate 13 Function of Major Components 14 Electronic Control System ECS 15 Display 16 DC DC Converter 21 Items 21 Outline Drawing 22 FuseReplacementProcedureandCheckingtheNormal Operation 22 Before You Operate 23 Diesel Fuel 23 Diesel Fuel Specifications 23 Filling the Fuel Tank 26 Bleeding the Fuel System 26 Engine Oil 27 Engine Oil Specifications ...

Page 4: ...iodic Maintenance 45 The Importance of Daily Checks 45 Keep a Log of Engine Hours and Daily Checks 45 Yanmar Replacement Parts 45 Tools Required 45 Ask Your Authorized Yanmar Marine Dealer for Help 45 Required EPA Maintenance USA Only 45 EPA Installation Requirements USA Only 46 Tightening Fasteners 46 Periodic Maintenance Schedule 47 Inspection and Maintenance of EPA Emission Related Parts 49 Per...

Page 5: ...ng Term Storage 69 Returning the Engine to Service 70 Specifications 71 Principal Engine Specifications 71 Wiring Diagrams 73 EPA Warranty USA Only 77 Yanmar Co Ltd Limited Emission Control System Warranty USA Only 77 Your Warranty Rights and Obligations 78 Warranty Period 78 Warranty Coverage 79 Exclusions 79 Owner s Responsibility 79 Customer Assistance 79 Maintenance Log 80 TABLE OF CONTENTS 6L...

Page 6: ...This Page Intentionally Left Blank TABLE OF CONTENTS vi 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

Page 7: ...procedures Keep this Operation Manual in a convenient place for easy access If this Operation Manual is lost or damaged order a new one from your authorized Yanmar Marine dealer or distributor Make sure this manual is transferred to subsequent owners This manual should be considered a permanent part of the engine and remain with it Constant efforts are made to improve the quality and performance o...

Page 8: ...ments to record the information you need when you contact Yanmar for service parts or literature Engine Model Engine Serial No Date Purchased Dealer Dealer Phone INTRODUCTION 2 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

Page 9: ...e same time 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 DANGER Indicates an hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious inj...

Page 10: ...y messages that follow have WARNING level hazards 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 authoriz...

Page 11: ...moving parts NEVER use the engine compartment for storage Sever Hazard Rotating parts can cause severe injury or death NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing and ALWAYS tie long hair back when working near moving rotating parts such as the flywheel or PTO shaft Keep hands feet and tools away from all moving parts Alcohol and Drug Hazard NEVER operate the engine while un...

Page 12: ...ne is operating in an enclosed area All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning CAUTION The safety messages that follow have CAUTION level hazards Poor Lighting Hazard Ensure that the work area is adequately illuminated ALWAYS install wire cages on portable safety lamps Tool Hazard ALWAYS use to...

Page 13: ...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 result of water entering the engine could cause seizure or other serious problems If you have an installation with two or three engi...

Page 14: ...t 0002079 5 1 2 1 4 3 Figure 1 1 Part Number 128296 07300 2 Part Number 120324 07240 3 Part Number 128296 07260 4 Part Number 128296 07350 5 Part Number 119578 07890 128296 07300 120324 07240 128296 07260 128296 07350 119578 07890 DO NOT STEP ON COVERS POSSIBILITY OF A FALL SAFETY 8 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

Page 15: ...nuals supplied by the shipyard and equipment manufacturers The laws of some countries may require hull and engine inspections depending on the use size and cruising area of the boat The installation fitting and surveying of this engine all require specialized knowledge and engineering skills See Yanmar s local subsidiary in your region or your authorized Yanmar Marine dealer or distributor This en...

Page 16: ...ction valve Perform this procedure in open waters With the clutch in NEUTRAL accelerate from the low speed position to the high speed position briefly Repeat this process five times Once past the initial 10 hours until 50 hours the engine should be used over its full operating range with special emphasis on running at relatively high power settings This is not the time for an extended cruise at id...

Page 17: ... 1 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 PRODUCT OVERVIEW 6LY3 LDC Operation Manual 11 2008 Yanmar Marine International ...

Page 18: ... 5 2 6 7 8 Figure 2 1 Coolant Tank Exhaust Manifold 2 Dipstick 3 Freshwater Cooler 4 Seawater Pump 5 Alternator 6 V Belt 7 Fuel Filter 8 Freshwater Pump PRODUCT OVERVIEW 12 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

Page 19: ... if damaged or lost Check the engine model output rpm and serial number on the nameplate 0006472 Gear Model ENG No Model min 1 min 1 min 1 Continuous power kW Speed of prop shaft Fuel stop power kW Figure 3 PRODUCT OVERVIEW 6LY3 LDC Operation Manual 13 2008 Yanmar Marine International ...

Page 20: ...ture rises the pressure rises inside the freshwater 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 from the coolant recovery tank This minimizes cooling water con ...

Page 21: ...Engines for a more complete description of the electronic control system ECS Start Eng ON OFF Emergency Stop Sub throttle active Sub throttle Model i2 Module 0002022 3 4 1 2 8 5 7 6 9 Figure 4 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 Gear 6 NMEA Tee and Terminators Kit 7 NMEA Tee Connector 8 ...

Page 22: ...the engine make it a rule to check for any highlighted alarms If the system does not function normally contact your authorized Yanmar Marine dealer and ask for diagnostics DUAL PORT Alarms HOT ENGINE OVER REV OIL PRESSURE TURBO BOOST GEAR OIL ENG COM ERROR MAINTENANCE NETWORK CHECK ENGINE EMERGENCY LOW VOLTAGE ALTERNATOR SEA WATER FLOW LOW COOLANT WATER IN FUEL THROTTLE PROBLEM 0002024 Figure 6 Al...

Page 23: ...of the rocker switch is pressed 2 Emergency Stop Figure 8 2 NOTICE Use this switch only in an emergency Under normal circumstances use the Eng ON switch Figure 8 1 to stop the engine The engine shuts down suddenly when the upper half of the Emergency Stop switch is pushed Push the bottom half of the switch after the engine has shut down to return the switch to the center Note Restarting the engine...

Page 24: ...re 11 4 in the helm station for AHEAD Figure 11 1 ASTERN Figure 11 3 NEUTRAL Figure 11 2 and speed control in a single installation 0002029 4 3 2 1 Figure 11 Control Head Button Functions N or NEUTRAL Button 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 a...

Page 25: ...teady grayed in Figure 12 3 Engaging Disengaging Shift Disconnect Mode N F R N F R N N SELECT SYNC N F R N F R N N SELECT SYNC N F R N F R N N SELECT SYNC N F R N F R N N SELECT SYNC N F R N F R N N SELECT SYNC 0002044 1 5 4 3 2 Figure 13 Engage 1 Return the handle s to N neutral The neutral light s glow steady Figure 13 1 2 Press the N neutral button s Figure 13 2 The neutral light s flash star a...

Page 26: ... 1 and press the N neutral button Figure 14 2 next to this lever on the control head The N neutral lamp Figure 14 2 will flash to indicate that the Split Range Throttle is engaged 2 While in the Split Range Throttle the system will shift normally but the throttle will be limited in both gears 3 If the system is shifted into neutral while in the Split Range Throttle engine mode the N neutral lamp w...

Page 27: ...vers are moved to within this 5 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 set to within 5 of each other and are above 20 throttle Disengage Press the SYNC button on the control head DC DC CONVERTER DC DC converter is a type of voltage converter which converts direct current elec...

Page 28: ... LA8Ø Terminal Fuse Replacement Procedure and Checking the Normal Operation Check the normal operation when the instrument pan el key switch is turned to the ON position Fuse replacement procedure Output side 13 8V 5 Replace the 15A glass tube in the 24V input side PRODUCT OVERVIEW 22 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

Page 29: ...ion Hazard on page 5 Diesel Fuel Specifications NOTICE Only use diesel fuels recommended by Yanmar Marine for the best engine performance to prevent engine damage and to comply with EPA warranty requirements Only use clean diesel fuel Diesel fuel should comply with the following specifications The table lists several worldwide specifications for diesel fuels DIESEL FUEL SPECIFICATION LOCATION No 2...

Page 30: ...tal rubber and plastic components of the fuel system The customer and or boat builder are responsible to verify the usage of biodiesel compatible components on the vessel fuel supply and return systems Free water in biodiesel may result in plugging of fuel filters and increased bacterial growth High viscosity at low temperatures may result in fuel delivery problems injection pump seizures and poor...

Page 31: ...el is stored be sure that the inside of the storage container is clean and dry and that the fuel is stored away from dirt or rain 0004512 Figure 1 2 Keep the fuel container stationary for several hours to allow any dirt or water to settle to the bottom of the container Use a pump to extract the clear filtered fuel from the top of the container Diesel Fuel Lines Installthelinesbetweenthe fueltankan...

Page 32: ...eeds to be bled under certain conditions Starting the engine for the first time After running out of fuel and fuel has been added to the fuel tank After fuel system maintenance such as changing the fuel filter and draining the fuel filter water separator or replacing a fuel system component To bleed the fuel system 1 Loosen the air bleed screw at the top of thefuel waterseparator2 3turns When fuel...

Page 33: ...etroleum Institute ACEA Classification Association des Constructeurs Européens d Automobilies JASO Japanese Automobile Standards Organization NOTICE Be sure the engine oil engine oil storage containers and engine oil filling equipment are free of sediment or water Change the engine oil after the first 50 hours of operation and then at every 250 hours thereafter Select the oil viscosity based on th...

Page 34: ...ng area before you remove the cap Remove the yellow oil filler port cap Figure 4 2 at the top of the rocker arm cover Figure 4 1 and fill with engine oil 2 Fill with engine oil to the upper limit Figure 4 4 on the dipstick Figure 4 3 Insert the dipstick fully to check the level NOTICE NEVER overfill the engine with engine oil Engine Lube Oil Capacity at rake 0 deg Full 18 8 L 19 9 quarts Effective...

Page 35: ...articles Without LLC cooling performance will decrease due to scale and rust in the coolant system Water alone may freeze and form ice it expands approximately 9 in volume Use 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 Exces...

Page 36: ...ve the coolant filler cap if the engine is hot Steam and hot engine coolant will spray out and seriously burn you Allow the engine to cool down before you attempt to remove the cap 0002067 2 3 1 Figure 7 3 NOTICE NEVER pour cold coolant into a hot engine Pour coolant mix slowly into the heat exchanger Figure 7 3 so that air bubbles do not develop Pour until the coolant overflows from the filler po...

Page 37: ...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 the connection an excessive amount of coolant will be lost 0002054 2 1 3 4 Figure 8 When engine coolant is supplied for the first time or when it has been replaced conduct a trial operation of the engine for about 5 minutes and check the quantity of engine oil and coolan...

Page 38: ...This Page Intentionally Left Blank BEFORE YOU OPERATE 32 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

Page 39: ... Hazard Be sure the boat is in open water away from other boats docks or other obstructions before increasing rpm Avoid unexpected equipment movement Shift the marine gear into the NEUTRAL position any time the engine is at idle To prevent accidental equipment movement NEVER start the engine in gear Sever Hazard Keep children and pets away while the engine is operating Exhaust Hazard NEVER block w...

Page 40: ...in the ON position see your authorized Yanmar Marine dealer or distributor for service before operating the engine Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in extremely dusty conditions Avoid operating in the presence of chemical gases or fumes NEVER run the engine if the ambient temperature is above 40C...

Page 41: ... 2006 TELEFLEX INC 0002057 i5601E Figure 2 5 Press the Eng ON Figure 3 1 switch and the following changes occur Start Eng ON OFF Emergency Stop Sub throttle active Sub throttle 0002058 1 Figure 3 The needle appears in the engine tachometer on the display 0 1 2 3 4 WTR TEMP X1000 RPM PSi 8 4 2615 0 100 100 250 1 1 4 Fah SINGLE OIL PRES 0002060 Figure 4 To Start the Engine To start the engine press ...

Page 42: ...on Be sure to re open the seacock and restart the engine Operate the engine normally After the Engine has Started After the engine has started check the following items at a low engine speed 1 Check that the indicators on the display and the control head are normal 2 Check for water or oil leakage from the engine 3 Check that exhaust color engine vibrations and sound are normal 4 When there are no...

Page 43: ...en FORWARD and REVERSE bring the clutch to NEUTRAL and pause before slowly shifting to the desired position Do not shift abruptly from FORWARD to REVERSE or vice versa 3 Move the control lever accurately into the FORWARD NEUTRAL and REVERSE positions F R N SEL N 0002061 5 3 4 6 1 2 Figure 5 Ahead Gradually move the control lever in the F forward direction Figure 5 2 to the position of the Forward ...

Page 44: ...oise CAUTION Excessive vibration may cause damage to the engine marine gear hull and onboard equipment In addition it causes noticeable passenger and crew discomfort Carefully select engine mounts and propellers when you design Yanmar Marine engine applications Depending on the hull structure engine and hull resonance may suddenly become great at a certain engine speed range causing heavy vibratio...

Page 45: ... 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 life of the engine NOTICE NEVER turn off the battery switch if equipped or short the batter...

Page 46: ...tank cock 6 Close the seacock 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 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 0C 32F Electric Emergency Stop CAUTION NEVER use the Emergency Stop switch for a normal engine s...

Page 47: ...in the display After the engine is shut down return the stop lever to the former position 1 0002063 2 Figure 7 CHECKING THE ENGINE AFTER OPERATION Check that the starter switch is in the OFF position and battery master switch if equipped is turned to OFF Fill the fuel tank See Filling the Fuel Tank on page 26 Close seawater cock s If there is a risk of freezing check that the cooling system contai...

Page 48: ...This Page Intentionally Left Blank ENGINE OPERATION 42 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

Page 49: ...Crush Hazard If the engine needs to be transported for repair have a helper assist you attach it to a hoist and load it on a truck The engine lifting eyes are engineered to lift the weight of the marine engine only ALWAYS use the engine lifting eyes when lifting the engine Additional equipment is necessary to lift the marine engine and marine gear together ALWAYS use lifting equipment with suffici...

Page 50: ...e gas during operation and special precautions are required to avoid carbon monoxide poisoning Shock Hazard ALWAYS turn off the battery switch if equipped or disconnect the negative battery cable before servicing the equipment ALWAYS keep the electrical connectors and terminals clean Check the electrical harnesses for cracks abrasions and damaged or corroded connectors NEVER use undersized wiring ...

Page 51: ...hours the engine is run each day and a log of the daily checks performed Also note the date type of repair e g replaced alternator and parts needed for any service needed between the periodic maintenance intervals Periodic maintenance intervals are every 50 250 500 1000 and 2000 engine hours Failure to perform periodic maintenance will shorten the life of the engine NOTICE Failure to perform perio...

Page 52: ...ent and not enough torque may cause a leak or component failure NOTICE The tightening torque in the Standard Torque Chart should be applied only to the bolts with a 7 head JIS strength classification 7T Apply 60 torque to bolts that are not listed Apply 80 torque when tightened to aluminum alloy Standard Torque Chart Bolt diameter x pitch mm M6x1 0 M8x1 25 M10x1 5 M12x1 75 M14x1 5 M16x1 5 Tighteni...

Page 53: ...ur authorized Yanmar Marine dealer or distributor for assistance when checking items marked with a Check or Clean Replace Contact your authorized Yanmar Marine dealer or distributor System Item Periodic Maintenance Interval Daily See Daily Checks on page 50 Every 50 hours or monthly whichever comes first Every 250 hours or three months whichever comes first Every 500 hours or six months whichever ...

Page 54: ...stem Replace zinc anode Air Intake and Exhaust System Clean the air intake silencer Clean the exhaust water mixing el bow Clean the turbocharger blower Flush aftercooler Electrical Sys tem Check the alarm indicators Check the electrolyte level in the battery Adjust the tension of the alternator V belt or replace V belt Check the wiring connectors Engine Cylinder Head and Block Check for leakage of...

Page 55: ...ern 3000 hours Check the fuel injection pump adjustment Check turbocharger adjustment Check the electronic engine control unit ECU and its associated sensors and actuators Note The inspection and maintenance items shown above should be performed at your Yanmar Marine dealer or distributor PERIODIC MAINTENANCE 6LY3 LDC Operation Manual 49 2008 Yanmar Marine International ...

Page 56: ... or corroded clamps 8 Check the fuel filter water separator for presence of water and contaminants If you find any water or contaminants drain the fuel filter water separator See Drain Fuel Filter and Fuel Filter Water Separator on page 53 If you 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 T...

Page 57: ...engine is operated on light diesel oil replace the fuel filter element every 250 hours or one year of operation 1 Close the fuel tank drain cock 2 Remove the center bolt Figure 1 1 at the bottom of the filter and take out the filter element Figure 1 2 3 Replace the element with a new one and tighten the center bolt Figure 1 1 1 2 0002078A Figure 1 4 Check for fuel leaks WARNING Avoid skin contact ...

Page 58: ...CE ALWAYS be environmentally responsible 3 Remove the engine oil filter Figure 2 1 with a filter wrench turn counterclockwise 4 Clean the filter installation face attach the new full flow oil filter and tighten by hand until the seal touches 5 Turnthefull flowoilfilteranadditional3 4 of a turn clockwise with the filter wrench 1 0002073 3 2 Figure 2 6 Fill with new engine oil See Adding Engine Oil ...

Page 59: ...hichever comes first Drain Fuel Filter and Fuel Filter Water Separator Check Battery Electrolyte Level Adjust Alternator V Belt Tension or Replace Alternator Belt Drain Fuel Filter and Fuel Filter Water Separator WARNING When removing any fuel system component to perform maintenance such as changing the fuel filter put an approved container under the opening to catch the fuel NEVER use a shop rag ...

Page 60: ...el filter water separator is provided in the hull in addition to those installed on the engine also drain and clean it or replace the element 5 After reassembly of the fuel filter water separator be sure to bleed air from the fuel system See Bleeding the Fuel System on page 26 6 Check for fuel leaks WARNING Avoid skin contact with the high pressure diesel fuel spray caused by a fuel system leak su...

Page 61: ...e destroyed Check the fluid level periodically If the level is lower than the minimum fill level Figure 5 1 fill with distilled water Figure 5 2 available in the grocery store up to the upper limit Figure 5 3 of the battery Battery fluid tends to evaporate in high temperatures especially in summer In such cases inspect the battery earlier than specified 2 Ifthe starterrpm istoo low andtheengine ca...

Page 62: ...ace the belt if it is damaged 2 3 1 0002077A Figure 6 1 Check the tension of the V belt by pressing on the middle of the belt Figure 6 1 with your finger With moderate force the V belt should deflect 8 10 mm approximately 3 8 in 2 If the V belt deflection is out of the limit adjust the V belt tension Loosen the adjuster bolt Figure 6 2 and move the alternator Figure 6 3 to adjust the V belt tensio...

Page 63: ... to adjust the intake exhaust valve clearance Drain the Fuel Tank Position an approved container under the fuel tank drain Open the drain cock and let the water dirt etc drain from the tank s bottom into the container Drain until fuel with no water and dirt flows out Close the drain cock See Filling the Fuel Tank on page 26 Replace the Fuel Filter Element See Replace the Fuel Filter Element on pag...

Page 64: ...r replacing the zinc anode varies depending on the characteristics of the seawater and operational conditions Inspect the zinc anode periodically and remove the corroded area on the surface Replace the zinc anode when it has decreased to less than 1 2 of the original volume If replacement of zinc anode is neglected and operation is continued with a corroded zinc anode corrosion of the seawater coo...

Page 65: ... and bolts to the standard tightening torques This inspection requires specializedknowledgeandtechniques See your authorized Yanmar Marine dealer or distributor to tighten major nuts and bolts Check Replace the Flexible Engine Mounts The rubber tension of the flexible engine mounts is lost after many hours of use This leads to a drop in vibration absorption performance and also causes centering mi...

Page 66: ...ized Yanmar Marine dealer or distributor Adjust the No Load Minimum Speed This maintenance requires specialized knowledge and techniques See your authorized Yanmar Marine dealer or distributor to adjust the no load minimum speed Every 1000 Hours of Operation Perform the following maintenance every 1000 hours or four years of operation whichever comes first Check the Fuel Injector Spray Pattern Cle...

Page 67: ...to a drop in vibration absorption performance and also causes centering misalignment of the propeller shaft Every 2000 Hours of Operation Perform the following maintenance every 2000 hours or eight years of operation whichever comes first Overhaul and Check Fuel Feed Pump Clean Engine Oil Cooler Clean Seawater and Engine Coolant System Replace Rubber Fuel Hoses Overhaul and Check Fuel Feed Pump Fu...

Page 68: ...e coolant systems Replace Rubber Fuel Hoses Rubberized fuel hoses tend to dry out and become brittle after 2000 hours or 2 years of engine operation whichever comes first See your authorized Yanmar Marine dealer or distributor to replace the rubber fuel hoses EPA REQUIREMENTS The EPA emission regulation is applicable only in USA EPA Certification Plates The engine has the EPA Certification Plates ...

Page 69: ...ter Replacing the fuel filter Cleaning the intake silencer air cleaner Note Inspections are divided into two sections in accordance with who is responsible for performing the inspection the user or the maker Inspection and Maintenance See Inspection and Maintenance of EPA Emission Related Parts on page 49 for the EPA emission related parts Inspection and maintenance procedures not shown in the Ins...

Page 70: ...This Page Intentionally Left Blank PERIODIC MAINTENANCE 64 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

Page 71: ... started check the following items at a low engine speed Is sufficient water being discharged from the seawater outlet pipe If the discharge is low stop the engine immediately Identify the cause and repair Is the exhaust color normal The continuous emission of black exhaust smoke indicates engine overloading This shortens the engineʼs life and should be avoided Are there abnormal vibrations or noi...

Page 72: ...d while underway This will generate higher exhaust temperatures which will help clean out hard carbon deposits maintain engine performance and prolong the life of the engine TROUBLESHOOTING INFORMATION If your engine does not operate properly refer to the Troubleshooting Chart or see your authorized Yanmar Marine dealer or distributor Supply the authorized Yanmar Marine dealer or distributor with ...

Page 73: ...ficulties 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 distributors Alarm indicator comes on Circuit broken Note Alarm indicator only comes on when there is an abnormality See your authorized Yanmar Marine dealer or distributor 2 When the...

Page 74: ...This Page Intentionally Left Blank TROUBLESHOOTING 68 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

Page 75: ...rain the coolant system A full coolant system will prevent corrosion and frost damage 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 1 Loosen the seawater drain cocks Figure 1 1 Figure 2 1 and drain the seawater 1 0002064 Figure 1 1 0002072 Figure 2 If no liquid comes from the drain cocks it may b...

Page 76: ... 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 rain and seawater from entering 7 During long term storage charge the battery once a month to compensate for the battery s self discharge RETURNING THE ENGINE TO SERVICE 1 Replace the oil and the oil filter before running the engine 2 Supply fuel if the fuel ...

Page 77: ...95 kW 400 hp 254 kW 345 hp Maximum Rated Output Output at Crankshaft Engine Speed 3300 min 1 rpm 316 kW 430 hp 273kW 370 hp at fuel inlet temp 40 C 104 F High Idling 3500 25 min 1 rpm Low Idling 700 25 min 1 rpm Installation Flexible mounting Direction of Rotation Crankshaft Counterclockwise viewed from stern Cooling System Liquid cooling with heat exchanger Normal Operating Temperature Range 71 t...

Page 78: ...Overall Height 776 6 mm 30 6 in Engine Dry Mass without marine gear 640 kg 1410 96 lb Recommended Battery Capacity 12V 150AH or more24V 120AH or more option Notes 1 Rating condition ISO 8665 Temperature of fuel 40 C 104 F at fuel pump inlet 2 1 hp metric horsepower 0 7355 kW 3 Fuel condition Density at 15 C 59 F 0 860 g cm3 53 67 lb ft3 Fuel temperature at the inlet of the fuel injection pump 4 Th...

Page 79: ...Wiring Diagrams Wiring Diagram 12 V SPECIFICATIONS 6LY3 LDC Operation Manual 73 2008 Yanmar Marine International ...

Page 80: ...ND SLD4 B 0 5 SLD1 B 0 5 SLD3 B 0 5 SLD2 B 0 5 B13F WR 1 25 B13G WR 1 25 J MW3 J MW2 ＥＥＥＥＥＥＥＥＥＥＥ B14 Gr 1 25 E61 LR 0 5 B21 GR 1 25 B13N WR 1 25 Inj pump actuator relay Normally open G11A BBr 0 5 ＥＥＥＥＥＥＥＥＥＥＥ 70A 50A ＥＥＥＥ ＥＥＥＥ ＥＥＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥ ＥＥＥ ECU ＥＥＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥＥＥＥＥＥ J MT1 ＥＥＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥＥＥＥＥＥ ＥＥＥＥＥＥＥＥＥＥ ＥＥ ＥＥＥＥＥＥＥＥＥ ...

Page 81: ...Wiring Harness Pin Location for 24 V Optional 0006653 SPECIFICATIONS 6LY3 LDC Operation Manual 75 2008 Yanmar Marine International ...

Page 82: ...This Page Intentionally Left Blank SPECIFICATIONS 76 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

Page 83: ...STEM 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 For Commercial Use 0006536 119578 07701 Figure 1 6LY3 LDC Operation Manual 77 2008 Yanmar Marine International ...

Page 84: ...condition exists Yanmar will repair your engine at no charge to you for diagnosis parts and labor Warranty service or repair will be provided at authorized Yanmar Marine engine dealers or distributors It is recommended that any replacement parts used or maintenance repair or replacement of emission control systems are Yanmar parts The owner may elect to have maintenance replacement or repair of th...

Page 85: ...ce 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 your failure to ensure the performance of all scheduled...

Page 86: ...Maintenance Log Date Operating Hours Maintenance Performed Dealer Name Stamp or Signa ture EPA WARRANTY USA ONLY 80 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

Page 87: ...Date Operating Hours Maintenance Performed Dealer Name Stamp or Signa ture EPA WARRANTY USA ONLY 6LY3 LDC Operation Manual 81 2008 Yanmar Marine International ...

Page 88: ...This Page Intentionally Left Blank EPA WARRANTY USA ONLY 82 6LY3 LDC Operation Manual 2008 Yanmar Marine International ...

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