Yanmar 6LY3-ETP, 6LY3-STP, 6LY3-UTP Service Manual

6LY3

series

6LY3 Service Manual

SERVICE MANUAL

P/N: 0BLY3-U00100

MARINE

ENGINES

This Service Manual has been developed for the exclusive use of service and repair professionals such as Yanmar authorized distributors and Yanmar authorized dealers. It is written with these professionals in mind and may not contain the necessary detail or safety statements that may be required for a non-professional to perform the service or repair properly and / or safely. Please contact an authorized Yanmar repair or service professional before working on your Yanmar product.

Disclaimers:

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

Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries.

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.

1107

ii 6LY3 Service Manual

TABLE OF

CONTENTS

Page

Introduction ......................................................................................... 1-1

Safety.................................................................................................... 2-1

General Service Information .............................................................. 3-1

Periodic Maintenance ......................................................................... 4-1

Engine .................................................................................................. 5-1

Fuel System ......................................................................................... 6-1

Coolant System ................................................................................... 7-1

Lubrication .......................................................................................... 8-1

Turbocharger....................................................................................... 9-1

Starter................................................................................................. 10-1

Alternator ........................................................................................... 11-1

Electrical and ECU ............................................................................ 12-1

Troubleshooting................................................................................ 13-1

Service Standards............................................................................. 14-1

6LY3 Service Manual

iii

TABLE OF CONTENTS

This Page Intentionally Left Blank

iv 6LY3 Service Manual

6LY3 Service Manual

INTRODUCTION

Section 1

This manual gives specific instructions for the proper repair of Yanmar 6LY3 series marine engines.

Please follow the procedures carefully to ensure quality service.

Yanmar recommends reading this Service Manual completely before starting with repairs.

Along with standard tools, Yanmar recommends the use of special tools necessary to perform repairs correctly.

Yanmar products are continuously undergoing improvement. This Service Manual has been checked carefully in order to avoid errors. However, Yanmar is not liable for any misrepresentations, errors of description or omissions. Contact your authorized Yanmar marine dealer or distributor for any questions you have regarding this Service

Manual.

6LY3 Service Manual

1-1

INTRODUCTION

REVISION HISTORY

Revision History

This manual is a living document. Periodic manual revisions are published to document product improvements and changes. This practice ensures the manual has the most current information.

As manual revisions become necessary, individual pages are prepared and sent to those who need the information. If a page or number of pages should be replaced, the replacement information is sent along with a revised Revision Control Table. Discard the older, obsolete information.

Revision Control Table

Revision Date

Revision Number

Aug. 2007

Rev. 0

New Page Numbers

Involved

ALL Initial Release YMI

At times, the revision involves inserting additional pages in one or more sections. Replace the Revision Control Table and insert the new pages.

This method of revision control represents the most cost-effective solution to providing current, updated information as needed.

Remarks

Initiating

Department

1-2 6LY3 Service Manual

6LY3 Service Manual

SAFETY STATEMENTS

Section 2

SAFETY

Yanmar is concerned for your safety and the condition of your marine engine. Safety statements are one of the primary ways to call your attention to the potential hazards associated with Yanmar marine engines. Follow the precautions listed throughout the manual before operation, during operation and during periodic maintenance procedures for your safety, the safety of others and to protect the performance of your marine engine. Keep the decals from becoming dirty or torn and replace them if they are lost or damaged. Also, if a part needs to be replaced that has a decal attached to it, make sure to order the new part and decal at the same time.

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.

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a situation which can cause damage to the engine, personal property and / or the environment or cause the equipment to operate improperly.

6LY3 Service Manual

2-1

SAFETY

SAFETY PRECAUTIONS

Safety Precautions

There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operating, performing repairs or maintenance.

The safety messages that follow have DANGER level hazards. These safety messages describe a hazardous situation which, if not avoided, will result in death or serious injury.

NEVER permit anyone to install or operate the engine without proper training.

• Read and understand this Service Manual before

operating or servicing the engine to ensure that safe operating practices and maintenance procedures are followed.

The safety messages that follow have WARNING level hazards. These safety messages describe a hazardous situation which, if not avoided, could result in death or serious injury.

Explosion Hazard

While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited. Keep the area around the

battery well-ventilated and keep sparks, open flame and any other form of ignition out of the area.

ALWAYS turn off the battery switch (if equipped) or disconnect the negative (-) battery cable before servicing the equipment.

Fire and Explosion Hazard

Diesel fuel is flammable and explosive under certain conditions.

• Safety signs and decals are additional reminders for safe operating and maintenance techniques.

• See your authorized Yanmar marine dealer or distributor for additional training.

Crush Hazard

NEVER stand under a hoisted engine. If the hoist mechanism fails, the engine will fall on you.

ALWAYS secure the engine solidly to prevent the engine from falling during maintenance.

NEVER use a shop rag to catch the fuel.

Wipe up all spills immediately.

NEVER refuel with the engine running.

Store any containers containing fuel in a well-ventilated area, away from any combustibles or sources of ignition.

2-2 6LY3 Service Manual

Safety Precautions

12/05

Fire Hazard

Have appropriate safety equipment available. Have all fire extinguishers checked periodically for proper operation and / or readiness.

ALWAYS read and follow safety-related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers.

Undersized wiring systems can cause an electrical fire.

Entanglement Hazard

NEVER leave the key in the key switch when servicing the engine. Attach a “Do Not Operate” tag near the key switch while performing maintenance on the equipment.

ALWAYS stop the engine before beginning service.

If the engine must be serviced while it is operating, remove all jewelry, tie back long hair and keep hands, other body parts and clothing away from moving / rotating parts.

SAFETY

Piercing Hazard

Avoid skin contact with high-pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line. High-pressure fuel can

penetrate your skin and result in serious injury. If you are exposed to high-pressure fuel spray, obtain prompt medical treatment.

NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar marine dealer or distributor repair the damage.

Flying Object Hazard

ALWAYS wear eye protection when servicing the engine or when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.

Coolant Hazard

Wear eye protection and rubber gloves

when handling Long Life Coolant (LLC).

If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water.

6LY3 Service Manual

2-3

SAFETY

Sever Hazard

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.

The propeller may rotate during towing or if the engine is running at idle speed. NEVER service the engine while being towed or when the engine is running.

If the vessel has more than one engine, NEVER service an engine if either of the engines is running. In multi-engine configurations the propeller for an engine that is shut down may rotate if any of the other engines are running.

Safety Precautions

ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions and damaged or corroded connectors.

NEVER turn off the battery switch (if equipped) or short the battery cables during operation. Damage to the electrical system will result.

Exhaust Hazard

All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning.

• NEVER block windows, vents or other means of ventilation if the engine is operating in an enclosed area.

• ALWAYS ensure that all connections are tightened to specifications after repair is made to the exhaust system.

Electrical Hazard

Make welding repairs safely.

• ALWAYS turn off the battery switch (if equipped) or disconnect the negative (-) battery cable and the leads to the alternator when welding on the equipment.

• Remove the multi-pin connector to the engine control unit. Connect the weld clamp to the component to be welded and as close as possible to the welding point.

• NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket.

• When welding is complete, reconnect the leads to the alternator and engine control unit prior to reconnecting the batteries.

Burn Hazard

Some of the engine surfaces become very hot during operation and shortly after shutdown.

• Keep hands and other body parts away from hot engine surfaces.

• Handle hot components with heat-resistant gloves.

2-4 6LY3 Service Manual

Safety Precautions

12/05

SAFETY

Sudden Movement Hazard

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.

Lifting Hazard

Additional equipment is necessary to lift the marine engine and marine gear together. ALWAYS use lifting equipment with sufficient capacity to lift the marine engine.

If transport is needed for engine repair, have a helper assist in attaching it to a hoist and loading it onto a truck.

Alcohol and Drug Hazard

NEVER operate the engine while under the influence of alcohol, drugs or when ill.

The safety messages that follow have CAUTION level hazards. These safety messages describe a hazardous situation which, if not avoided, could result in minor or moderate injury.

ALWAYS wear eye protection when servicing the engine or when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes.

Poor Lighting Hazard

Ensure that the work area is adequately illuminated. ALWAYS install wire cages on portable safety lamps.

Too l Haza rd

ALWAYS use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts.

Exposure Hazard

ALWAYS wear personal protective equipment including appropriate clothing, gloves, work shoes, eye and hearing protection as required by the task at hand.

Too l Haza rd

ALWAYS remove any tools or shop rags used during maintenance from the area before operation.

6LY3 Service Manual

2-5

SAFETY

The safety messages that follow have NOTICE level hazards.

Safety Precautions

NEVER dispose of hazardous materials by dumping them into a sewer, on the ground or into groundwater or waterways.

Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced.

ALWAYS tighten components to the specified torque. Loose parts can cause equipment damage or cause it to operate improperly.

Only use replacement parts specified. Other replacement parts may affect warranty coverage.

NEVER attempt to modify the engine design or safety features such as defeating the engine speed limit control or the diesel fuel injection quantity control.

NEVER attempt to adjust the low or high idle speed limit bolt. This may impair the safety and performance of the engine and shorten its life. Modifications of this type may void the warranty. If adjustment is ever required, contact your authorized Yanmar marine dealer or distributor.

If any indicator illuminates during engine operation, stop the engine immediately. Determine the cause and repair the problem before continuing to operate the engine.

Make sure the 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 Installation Manuals, 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.

Modifications may impair the engine’s safety and performance characteristics and shorten the engine’s life. Any alterations to this engine may void its warranty. Be sure to use Yanmar genuine replacement parts.

Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil, diesel fuel and engine coolant. Consult the local authorities or reclamation facility.

2-6 6LY3 Service Manual

Location of Safety Decals

12/05

LOCATION OF SAFETY DECALS

Figure 2-1 shows the location of safety decals on Yanmar 6LY3 series marine engines.

Figure 2-1

(3)

(2)

NEVER pour the engine oil across

FULL LOW

(1)

(4)

the full line.

(5)

SAFETY

119773-07280

(6)

DO NOT STEP ON COVERS. POSSIBILITY

DO NOT STEP

OF A FALL

ON COVERS. POSSIBILITY OF A FALL

1 – Part Number: 128296-07300 2 – Part Number: 120324-07240 3 – Part Number: 119773-07280

003025-02E

0006329

Figure 2-1

4 – Part Number: 128296-07260 5 – Part Number: 128296-07350 6 – Part Number: 119578-07890

6LY3 Service Manual

2-7

SAFETY

Location of Safety Decals

This Page Intentionally Left Blank

2-8 6LY3 Service Manual

6LY3 Service Manual

Section 3

GENERAL SERVICE

INFORMATION

Safety Precautions .......................................................................... 3-3

6LY3-ETP Exterior Views................................................................ 3-4

Operation Side........................................................................... 3-4

Non-Operation Side................................................................... 3-4

Diesel Fuel ...................................................................................... 3-6

Diesel Fuel Specifications ......................................................... 3-6

Engine Oil........................................................................................ 3-8

Engine Oil Specifications........................................................... 3-8

Marine Gear Oil ............................................................................... 3-8

Page

Engine Coolant................................................................................ 3-9

Handling of Coolant................................................................... 3-9

Engine Outline Drawings............................................................... 3-10

6LY3-ETP / STP / UTP (YT-15 MOUNT) ................................ 3-10

6LY3-ETP................................................................................ 3-11

Exhaust Gas Emission Regulations .............................................. 3-12

Engine Identification ................................................................ 3-12

EPA Exhaust Gas Emission Standard..................................... 3-13

EPA Guarantee Conditions for Emission Standard................. 3-13

Engine Nameplate......................................................................... 3-14

Reduction and Reversing Gear ..................................................... 3-14

Principal Engine Specifications ..................................................... 3-15

Abbreviations and Symbols........................................................... 3-16

Abbreviations........................................................................... 3-16

Symbols................................................................................... 3-16

6LY3 Service Manual

3-1

GENERAL SERVICE INFORMATION

Unit Conversions........................................................................... 3-17

Unit Prefixes ............................................................................ 3-17

Units of Length ........................................................................ 3-17

Units of Volume ....................................................................... 3-17

Units of Mass........................................................................... 3-17

Units of Force .......................................................................... 3-17

Units of Torque........................................................................ 3-17

Units of Pressure..................................................................... 3-17

Units of Power ......................................................................... 3-17

Units of Temperature............................................................... 3-17

3-2 6LY3 Service Manual

Safety Precautions

12/05

GENERAL SERVICE INFORMATION

SAFETY PRECAUTIONS

Before servicing the engine review the Safety Section on page 2-1.

6LY3 Service Manual

3-3

GENERAL SERVICE INFORMATION

6LY3-ETP EXTERIOR VIEWS

Operation Side

Figure 3-1

(9)

6LY3-ETP Exterior Views

(1)

(2)

(8)

Non-Operation Side

Figure 3-2

(16)

(17)

(5)(6)(7)

Figure 3-1

(3)

(4)

0006254

(10)

(11)

3-4 6LY3 Service Manual

(13)

(14)

(15)

Figure 3-2

(12)

0006255

6LY3-ETP Exterior Views

12/05

GENERAL SERVICE INFORMATION

1 – Filler Cap 2 – Electrical Control Unit Cover 3 – Fuel Injection Pump 4 – Oil Cooler 5 – Oil Filter 6 – Intercooler 7 – Flywheel 8 – Air Silencer 9 – Turbocharger

10 – Coolant Tank (Exhaust Manifold) 11 – Dipstick 12–Heat Exchanger 13–Seawater Pump 14–Alternator 15–V-Belt 16 – Fuel Filter 17–Coolant Pump

6LY3 Service Manual

3-5

GENERAL SERVICE INFORMATION

Diesel Fuel

DIESEL FUEL

Diesel Fuel Specifications

NOTICE: Use the correct fuel type to maintain engine performance and reduce engine wear and ensure compliance with emission regulations.

Fuel Selection

Diesel fuel should comply with the following specifications:

• The fuel specifications need to comply with national and international standards.

• ASTM D975 No. 1-D No. 2-D for USA

• EN590: 96 for EU

• ISO 8217 DMX International

• BS 2869-A1 or A2 for UK

• JIS K2204-2 for JAPAN

Additional Fuel Requirements

• Fuel cetane number should equal 45 or higher.

• Sulfur content should not exceed 0.5% by volume. (Preferably it should be below 0.05%.)

• Water and sediment in the diesel fuel should not exceed 0.05% by volume.

• Ash should not exceed 0.01% by mass.

• Carbon residue content of the diesel fuel should not exceed 0.35% by volume. (Preferably it should be below 0.1%.)

• Total aromatic content of the diesel fuel should not exceed 35% by volume. (Preferably it should be below 30% and aromatic polycyclic aromatic hydrocarbons (PAH*) content of the diesel fuel should be below 10%.)

NOTICE: Mixing winter and summer fuel, using Kerosene, residual fuel or Biocide produces poor fuel quality and will result in reduced engine performance and excessive wear of internal components.

3-6 6LY3 Service Manual

Diesel Fuel

12/05

GENERAL SERVICE INFORMATION

Handling Diesel Fuel

• Water and dust in the diesel fuel can cause operation failure. Use containers which are clean inside to store diesel fuel. Store the containers away from rain and dirt.

• Allow fuel to settle for several hours before pumping from container.

• Before refilling fuel, let the fuel container rest for several hours so that water and dust in the fuel are deposited on the bottom. Use only clean fuel. Use the clear filtered fuel from the upper middle section of the container only (Figure 3-3), leaving any contaminated fuel at the bottom.

Figure 3-3

0006257

Figure 3-3

Diesel Fuel Lines

Install the fuel supply line between the fuel tank and the fuel injection pump. Install a drain cock at the bottom of the fuel tank to remove water and dust. Install a fuel / water separator and a fuel filter in the middle of the fuel supply line.

Figure 3-4

(1)

(10)

(8)

(9)

Figure 3-4

1 – Diesel Fuel Strainer 2 – Diesel Fuel Return Pipe 3 – Diesel Fuel Tank 4 – Drain Cock 5 – Diesel Fuel Shutoff Valve 6 – Approximately 500 mm (20 in.) 7 – Fuel / Water Separator 8 – Diesel Fuel Priming Pump 9 – Less than 500 mm (20 in.)

10 – To Diesel Fuel Injection Pump

(7)

(2)

(5)

(3)

(6)

(4)

0006256

6LY3 Service Manual

3-7

GENERAL SERVICE INFORMATION

Engine Oil

ENGINE OIL

Engine Oil Specifications

NOTICE: Use the correct engine oil to maintain engine performance and reduce engine wear.

Selection of Engine Oil

Use an engine oil that meets or exceeds the following classifications:

• API Service Category - CD or higher

• TBN Valve - 9 or more

• SAE viscosity - 15W40

If the engine is operated at temperatures below those shown in Figure 3-5, consult your Yanmar Marine dealer for special lubricants and starting aids.

Figure 3-5

Selection of viscosity (SAE Service grade)

10W

20W

10W-30

15W-40

#20

#30

#40

-20 -10 0 10 20 30 40 50

Atmospheric temperature (°C)

0006258

The following oils should not be used for 6LY3-ETP, STP or UTP engines:

• API: CG-4, CH-4

• ACEA: E-1, E-2, B

• JASO: DH-2, DL-1

Additional Technical Engine Oil Requirements

The engine oil must be changed when the Total Base Number (TBN) has been reduced to 2.0. TBN (mgKOH / g) test method; JIS K-2501-5.2-2 (HCI), ASTM D4739 (HCI).

Handling Engine Oil

1. Check that the engine oil, oil storage container and filling equipment are free of sediment and water.

2. NEVER mix engine oils of different types.

3. Extract any residual oil from the engine or marine gear before servicing for the first time. Always use fresh new oil.

4. Engine oil degrades over time, even when the engine is not in use. Change oil at specified times regardless of engine usage.

MARINE GEAR OIL

Refer to the Operation Manual for marine gear oil specifications.

Figure 3-5

3-8 6LY3 Service Manual

Engine Coolant

12/05

GENERAL SERVICE INFORMATION

ENGINE COOLANT

Mix clean deionized soft water with Long Life Coolant (LLC) in order to prevent rust buildup and freezing. NOTICE: NEVER use water only.

Freezing water will cause serious damage to the engine.

LLC must conform to the following specifications:

• JIS K-2234

• SAE J814C, J1941, J1034, J2036

• ASTM D3306

• ASTM D4985

Yanmar recommends using genuine Yanmar coolant / antifreeze. Contact your authorized Yanmar dealer or distributor.

Recommended Engine Coolants:

• TEXACO LONG LIFE COOLANT ANTIFREEZE, both standard and pre-mixed. Product code 79947 and 7998.

Handling of Coolant

1. Replace the coolant periodically, according to

the maintenance schedule in the Operation Manual.

2. Remove the scale from the coolant system periodically, according to the instructions for your engine.

NOTICE: Excessive mixture of LLC lowers the cooling efficiency of the engine. Use the mixing ratios specified by the LLC manufacturer for the temperature range in which you will be operating.

• HAVOLINE EXTENDED LIFE ANTIFREEZE / COOLANT. Product code 7994.

NOTICE:

• Always be sure to add LLC to soft water. It is particularly important to add LLC during cold weather. Without LLC, coolant performance will decrease due to scale and rust in the coolant system.

• Mix the proper amount of coolant concentrate specified by the LLC manufacturer for the ambient temperature in which you will be operating. LLC concentration should be between 30% and 60%.

• Mixing different types of LLC is harmful because it causes sludge buildup.

• NEVER use hard water.

• Use only clean deionized soft water when mixing

LLC.

6LY3 Service Manual

3-9

GENERAL SERVICE INFORMATION

ENGINE OUTLINE DRAWINGS

6LY3-ETP / STP / UTP (YT-15 MOUNT)

Figure 3-6

Unit : mm (in)

118

Direction of rotation

-0.035

ø95

()

ø 260

ø 150

21.5

Detail of front coupling

(801.3)

525.6

Engine Outline Drawings

621.3

(776.6)

538.6

420.3

381

238

39Min. 83

0006333

252

Max. 103

235

61.5

761

ø37 / ø46

(Without mixing elbow)

Water outlet

Depth 12

+0.015

()

ø10 H7

Parallel pin hole

6-M10 Depth 20

290

Water inlet ø38 / ø46

287287

8-M10 Depth 15

12-M10 Depth 19

279.1

287287

Mounting block

105

170

(Option)

210

ø18.5

740.5

6.9

ø314

ø 352.42

+0.13

ø 409.58

+0.13

Fuel filter

Fuel outlet

ø9 / ø16 fuel hose

Engine oil filters

321.5

Center of

crank shaft

(285)

786

740.5 (256.5)

Fuel inlet

1071

1300.4

ø9 / ø16 fuel hose

Center of gravity

170

450

Detail of flywheel output side

3-10 6LY3 Service Manual

333.38

428.6

Figure 3-6

Center of

crank shaft

NOTES:

1.Drawing Shows mounting blocks at original height.

(Engine weight will compress blocks by approximately 3.5mm)

2.Mounting block parts number is 127495-08320.

(YT-15 mount)

3. Shows center of gravity.

4.Mixing elbow rubber hose inner diameter 5 in.

Engine Outline Drawings

12/05

6LY3-ETP

Figure 3-7

Engine

GENERAL SERVICE INFORMATION

000633

Engine

Diesel fuel

Engine seawater Piping

Diesel fuel piping

Engine

Engine Coolant Piping

6LY3 Service Manual

Diesel fuel

Figure 3-7

Engine coolant

pump

NOTES:

3-11

GENERAL SERVICE INFORMATION

Exhaust Gas Emission Regulations

EXHAUST GAS EMISSION REGULATIONS

6LY3 series engines are applicable with Marine Compression Ignition Engines Regulation of the EPA (40 CFR Part 94) in the U.S. RCD Regulation and BSO Regulation in Europe and other regulations are applied to this engine.

Engine Identification

With the regulations on exhaust gas emission worldwide, it has become necessary to identify engines in a manner that determines which regulations they comply with.

EPA Emission Labels and Location

Figure 3-8

MARINE ENGINE EMISSION CONTROL INFORMATION

THIS ENGINE COMPLIES TO U.S. EPA REGULATIONS 40 CFR PART 94 WHICH APPLY TO MARINE ENGINES

MODEL YEAR : 2006 MODEL: 6LY3-ETP, STP, UTP

DISPLACEMENT PER CYLINDER : 0.969 LITERS

ENGINE FAMILY : 6YDXM5.81D6H STANDARDS THC+NOx : 7.2g/kWh CO : 5.0g/kWh PM : 0.30g/kWh

REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.

APPLICATION : RECREATIONAL

THIS ENGINE IS CATEGORIZED AS A RECREATIONAL MARINE ENGINE UNDER 40 CFR PART 94. INSTALLATION OF THIS ENGINE IN ANY NONRECREATIONAL VESSEL IS A VIOLATION OF FEDERAL LAW SUBJECT TO CIVIL PENALTY.

Recreational marine engine label

Emission control label

0006259

Figure 3-8

3-12 6LY3 Service Manual

Exhaust Gas Emission Regulations

12/05

GENERAL SERVICE INFORMATION

EPA Engine Family Name as Assigned by EPA Identifying Engine Family Group

Figure 3-9

6 YDX M 5.81 D 6 H

Method of air aspiration

Number of cylinders

Combustion chamber design

Displacement (liter)

Marine engine

Yanmar

2006 Model Year

Figure 3-9

0006260

EPA Exhaust Gas Emission Standard

Engine Power Category Tier Model Year NMHC + NOx CO PM

37 kW (50.3 hp) and

Above

0.9-1.2 L / cylinder Tier 2 2006

7.2 g / kWh

(0.186 oz / hph)

5.0 g / kWh

(0.129 oz / hph)

0.3 g / kWh

(0.007 oz / hph)

NOTICE: The transit smoke (ACC / LUG / PEAK) is not applicable. The EPA recommended fuel is used. As for model year, the year which a regulation is applicable to for recreational use is shown.

EPA Guarantee Conditions for Emission Standard

In addition to making sure that these conditions are met, check for any deterioration that may occur before the required periodic maintenance times.

1. Fuel: The diesel fuel ASTM D975 No. 1-D or

No. 2-D, equivalent (Cetane No. 3.45 minimum).

2. Oil: API grade, class CD.

6LY3 Service Manual

3-13

GENERAL SERVICE INFORMATION

ENGINE NAMEPLATE

Figure 3-10 shows the location of the engine nameplate.

Figure 3-10

Model

Gear Model

Continuous power kW

Speed of prop,shaf t

Fuel sto p power kW

ENG.No.

min

-1

min

119175-7202

Engine Nameplate

-1

REDUCTION AND REVERSING GEAR

Refer to your Marine Gear Service Manual for inspection, disassembly and reassembly information.

0006420

Figure 3-10

3-14 6LY3 Service Manual

Principal Engine Specifications

12/05

GENERAL SERVICE INFORMATION

PRINCIPAL ENGINE SPECIFICATIONS

STP: 295 kW (401 hp) / 3198 rpm, UTP: 254 kW (345 hp) / 3198 rpm

Engine Model 6LY3-ETP 6LY3-STP 6LY3-UTP

Use Pleasure Use Type Vertical water-cooled, 4-cycle diesel engine Aspiration Turbocharger with Aftercooler Combustion System Direct injection Number of Cylinders 6 Firing Order 1-4-2-6-3-5 Bore x Stroke 105.9 × 110 mm (4.17 × 4.33 in.) Displacement 5.813 L (6.14 qt)

Output at Crankshaft

Continuous Rating Output

Maximum Output

High Idling (Note 3) 3500 ± 25 rpm Low Idling (Note 3) 700 ± 25 rpm Installation Flexible mounting Direction of Rotation Crankshaft Counterclockwise viewed from stern Coolant System Closed coolant system with heat exchanger Lubrication System Complete enclosed forced lubrication

Coolant Capacity

Starting System

Turbocharger

Engine Dimension

Engine Dry Mass (Without Marine Gear) 640 kg (1410.96 lb) Recommended Battery Capacity 12V-150Ah or more

Engine Speed (3198 rpm) (Notes 1 and 2)

Output at Crankshaft Engine Speed (3300 rpm) (Notes 1 and 2)

Rake Angle 0° Total (Note 4) 18.8 L (19.9 qt) Effective (Note 5) 8.0 L (8.5 qt) Type Electric Starting Motor DC 12V - 3 kW AC Generator 12V - 80A Model RHC7W (IHI made) Type Water cooled Overall Length 1300.4 mm (51.2 in.) Overall Width 801.3 mm (31.5 in.) Overall Height 776.6 mm (30.6 in.)

436 hp Metric

321 kW

480 hp Metric

353 kW

40°C (104°F) at fuel inlet temperature

Coolant recovery tank: 1.5 L (30 qt)

3198 rpm

401 hp Metric

295 kW

3300 rpm

441 hp Metric

324 kW

Engine: 28 L (30 qt)

345 hp Metric

254 kW

379 hp Metric

279 kW

Notes:

1. Rating condition: ISO 8665. Temperature of fuel: 40°C (104°F) at the fuel pump inlet.

2. 1 hp (metric horsepower) = 0.7355 kW

3. Fuel condition: Density at 15°C (59°F) = 0.860 g/cm

4. Fuel temperature at the inlet of the fuel injection pump.

5. The “Total Engine Oil Capacity” includes the oil in the oil pan, channels, coolers and filter.

6. The “Effective Engine Oil Capacity” indicates the difference in maximum scale of the dipstick and

minimum scale.

6LY3 Service Manual

(53.69 ft·lb3).

3-15

GENERAL SERVICE INFORMATION

ABBREVIATIONS AND SYMBOLS

Abbreviations and Symbols

Abbreviations

A ampere AC alternating current ACEA Association des Constructeurs

Européens d’Automobilies

Ah ampere-hour API American Petroleum Institute ARB Air Resources Board ATDC after top dead center BDC bottom dead center BTDC before top dead center °C degree Celsius CARB California Air Resources Board CCA cold cranking amp cfm cubic feet per minute cm centimeter

/min. cubic centimeter per minute cu in. cubic inch D diameter DC direct current DI direct DVA direct volt adapter EPA Environmental Protection Agency ESG electronic speed governor °F degree Fahrenheit fl oz fluid ounce (U.S.) fl fluid ounce (U.S.) per minute ft foot ft-lb foot pound* ft-lbf/min. foot pound force per minute g gram gal gallon (U.S.) gal/hr gallon (U.S.) per hour gal/min. gallon (U.S.) per minute GL gear lubricant hp horsepower (metric) hr hour ID inside diameter ID identification IDI indirect injection in. inch inAq inches Aqueous (water) in. Hg inches Mercury in.-lb inch pound** J joule JASO Japanese Automobile Standards

K kelvin kg kilogram

cubic centimeter

Organization

kgf/cm

kgf·m kilogram force per meter km kilometers kPa kilopascal kW kilowatt L liter L/hr liter per hour lb pound lbf pound-force lb-ft pound foot (Tightening Torque) lb-in pound inch (Tightening Torque) m meter mL milliliter mm millimeter mmAq millimeter Aqueous (water) MPa megapascal mV millivolt N newton N No. number O.D. outside diameter oz ounce Pa pascal PS horsepower (metric) psi pound per square inch qt quart (U.S.) R radius rpm revolutions per minute SAE Society of Automotive Engineers sec. second t short ton 2000 lb TBN total base number TDC top dead center V volt VAC volt alternating current VDC volt direct current W watt

kilogram force per square centimeter

·m newton meter

Symbols

° degree + plus

- minus ± plus or minus

Ω ohm μ micro

% percent

* Work torque such as engine torque ** Work torque such as starter motor torque

3-16 6LY3 Service Manual

+ 360 hidden pages

Yanmar 6LY3-ETP, 6LY3-STP, 6LY3-UTP Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual