Yanmar 6LY3-STC, 6LY3-UTC Operation Manual

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Page 1

MARINE

ENGINE

6LY3

series

OPERATION MANUAL

6LY3–STC 6LY3–UTC

P/N: 0ALY3–G00200

Page 2

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 without notice. 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.

0808

6LY3 LDC Operation Manual

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TABLE OF

CONTENTS

Page

Introduction......................................................................1

Record of Ownership......................................................2

Safety...............................................................................3

Safety Precautions.........................................................4

General Information ................................................. 4

Before You Operate .................................................4

During Operation and Maintenance .............................4

Location of Labels..........................................................8

Product Overview..............................................................9

Yanmar 6LY3 Features and Applications.............................9

New Engine Break-In................................................9

Component Identification...............................................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

Fuse Replacement Procedure and Checking the Normal

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......................................... 27

Engine Oil Viscosity ............................................... 28

6LY3 LDC Operation Manual

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Page 4

Checking Engine Oil............................................... 28

Adding Engine Oil.................................................. 28

Selection of Marine Gear Oil .................................... 28

Engine Coolant............................................................29

Filling Heat Exchanger with Engine Coolant................. 30

Engine Operation.............................................................33

Starting the Engine.......................................................35

Before Starting the Engine....................................... 35

To Start the Engine ................................................ 35

If the Engine Fails to Start........................................ 36

After the Engine has Started .................................... 36

Shifting................................................................ 37

Neutral ................................................................ 37

Ahead................................................................. 37

Astern ................................................................. 37

Cautions During Operation.............................................38

Shutting Down the Engine..............................................40

Normal Shutdown.................................................. 40

Checking the Engine After Operation................................41

Periodic Maintenance.......................................................43

Safety Precautions.......................................................43

Precautions.................................................................45

The Importance of Periodic Maintenance .................... 45

Performing Periodic 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

Periodic Maintenance Procedures....................................50

Daily Checks ........................................................ 50

After Initial 50 Hours of Operation.............................. 51

Every 50 Hours of Operation .................................... 53

Every 250 Hours of Operation .................................. 57

Every 500 Hours of Operation .................................. 60

Every 1000 Hours of Operation................................. 60

Every 2000 Hours of Operation................................. 61

EPA Requirements.......................................................62

EPA Certification Plates .......................................... 62

TABLE OF CONTENTS

6LY3 LDC Operation Manual

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Conditions to Ensure Compliance with EPA Emission

Standards............................................................ 63

Inspection and Maintenance .................................... 63

Troubleshooting..............................................................65

Troubleshooting After Starting.........................................65

Troubleshooting Information........................................... 66

Troubleshooting Chart...................................................67

Long-Term Storage..........................................................69

Before You Place the Engine in Long-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

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This Page Intentionally Left Blank

TABLE OF CONTENTS

6LY3 LDC Operation Manual

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INTRODUCTION

Welcome to the world of Yanmar Marine! Yanmar Marine offers engines, drive systems and accessories for all types of boats, from runabouts to sailboats, and from cruisers to mega yachts. In marine light duty commercial boating, the worldwide reputation of Yanmar Marine is second to none. We design our engines to respect nature. This means quieter engines, with minimal vibrations, cleaner than ever. All of our engines designed after 1996 meet most of the present and future emission regulations, like BSO II, SAV, EPA II, IMO and RCD.

To help you enjoy your Yanmar 6LY3 engine for many years to come, please follow these recommendations:

• Read and understand this Operation Manual before you operate the machine to ensure that you follow safe operating practices and maintenance procedures.

• Keep this Operation Manual in a convenient place for easy access.

• If this Operation Manual is lost or damaged, order a new one from your authorized Yanmar Marine dealer or distributor.

• Make sure this manual is transferred to subsequent owners. This manual should be considered a permanent part of the engine and remain with it.

• Constant efforts are made to improve the quality and performance of Yanmar products, so some details included in this Operation Manual may differ slightly from your engine. If you have any questions about these differences, please contact your authorized Yanmar Marine dealer or distributor.

• The specifications and components (instrument panel, fuel tank, etc.) described in this manual may differ from ones installed on your vessel. Please refer to the manual provided by the manufacturer of these components.

• Refer to the Yanmar Limited Warranty Handbook for a complete warranty description.

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RECORD OF OWNERSHIP

Take a few moments to record the information you need when you contact Yanmar for service, parts or literature.

Engine Model: Engine Serial No.: Date Purchased: Dealer: Dealer Phone:

INTRODUCTION

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SAFETY

Yanmar considers safety of great importance and recommends that anyone that comes into close contact with its products, such as those that install, operate, maintain or service Yanmar products, exercise care, common sense and comply with the safety information in this manual and on the machine’s safety labels. Keep the labels from becoming dirty or torn and replace them if they are lost or damaged. Also, if you need to replace a part that has a label attached to it, make sure you order the new part and label at the same time.

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 injury.

CAUTION

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

NOTICE

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

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SAFETY PRECAUTIONS

General Information

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 operation or performing repairs or maintenance.

Before You Operate

DANGER

The safety 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 authorized Yanmar Marine dealer or distributor for additional training.

During Operation and Maintenance

DANGER

The safety message that follows has DANGER level hazards.

Crush Hazard

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

SAFETY

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WARNING

The safety messages that follow have WARNING level hazards.

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 flames and any other form of ignition out of the area.

Fire and Explosion Hazard

Diesel fuel is flammable and explosive under certain conditions.

NEVER use a shop rag to catch the fuel.

Wipe up all spills immediately.

NEVER refuel with the engine running.

NEVER use diesel fuel as a cleaning agent.

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

Fire Hazard

Undersized wiring systems

can cause an electrical fire.

Store any equipment in a designated area away from 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 under the influence of

alcohol or drugs or feeling ill.

Exposure Hazard

ALWAYS wear personal

protective equipment

including appropriate

clothing, gloves, work shoes,

eye and hearing protection as required by the task at hand.

Entanglement Hazard

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.

NEVER operate the engine while wearing a headset to listen to music or radio because it will be difficult to hear the warning signals.

SAFETY

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WARNING

Piercing Hazard

Avoid skin contact with highpressure 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.

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.

Sudden Movement Hazard

ALWAYS stop the engine before beginning service.

Exhaust Hazard

NEVER block windows, vents

or other means of ventilation if

the engine is operating in an

enclosed area. All internal

combustion engines create carbon monoxide gas during operation 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 tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts.

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 you handle Long Life engine coolant. If contact with the

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

SAFETY

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NOTICE

The safety messages that follow have NOTICE level hazards.

It is important to perform daily checks as listed in the Operation Manual. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine performance and helps extend the life of the engine.

See your authorized Yanmar Marine dealer or distributor if you need to operate the engine at high altitudes. At high altitudes the engine will lose power, run rough and produce exhaust gases that exceed the design specifications.

ALWAYS be environmentally responsible.

Follow the guidelines of the EPA or other governmental

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

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

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.

If you have an installation with two or three engines and only one engine is operating, the water pickup (thru-hull) of the nonrunning 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 engines, and only one engine is operating, please note that if the propeller shaft thruhull (stuffing box) is lubricated by engine water pressure and the engines are interconnected, care must be taken that water from the running engine does not enter the exhaust of the non-running engine(s). This water could cause seizure of the non-running engine(s). See your authorized Yanmar Marine dealer or distributor for a complete explanation of this condition.

If you have an installation with two or three engines, and only one engine 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 excess carbon buildup which may shorten the engine’s life.

SAFETY

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LOCATION OF LABELS

Figure 1 shows the location of regulatory

and safety labels on Yanmar 6LY3 series engines. Please replace if damaged or lost.

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

6LY3 LDC Operation Manual

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PRODUCT OVERVIEW

YANMAR 6LY3 FEATURES AND APPLICATIONS

The engine is equipped with a marine gear. The marine gear output shaft connects with the propeller shaft. In order to obtain full performance from your engine, it is imperative that you check the size and structure of the hull and use a propeller of the appropriate size. As new boats are used, owners add additional equipment and completely fill the fuel and water tanks, adding to the overall displacement (weight) of the vessel. Extra canvas enclosures, bottom paint and bottom fouling can add additional hull resistance. It is recommended that a new vessel be propped so the engine operates at 95% load at 3300 rpm. Failure to do so can lead to reduced vessel performance, lead to increased smoke levels and cause permanent damage to your engine.

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 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 engine is designed for light duty commercial applications. The engine is designed to be operated at maximum throttle (3300 rpm) for less than 5% of its total operation time (30 minutes out of every 10 hours). The engine should be operated at cruising speed (3200 rpm) for less than 90% of its total operation time (9 hours out of every 10 hours).

New Engine Break-In

As with all reciprocating engines, the way your engine is operated during its first 50 hours of operation plays a very significant role in determining how long it will last and how well the engine will perform over its lifetime.

A new Yanmar diesel engine must be operated at suitable speeds and power settings during the break-in period to make the sliding parts, such as piston rings, break in properly and to stabilize engine combustion.

During the break-in period, the engine coolant temperature gauge should be monitored; temperature should be between 71 and 87C (160 and 190F).

6LY3 LDC Operation Manual

Page 16

During the first 10 hours of operation, the engine should be run at maximum rpm minus 400 - 500 rpm (approximately 60 - 70% of load) most of the time. This will ensure the sliding parts break in properly. During this period, avoid operating at maximum engine speed and load to avoid damaging or scoring sliding parts.

NOTICE: Do not operate at WOT (wide open

throttle) for more than a minute at a time during the first 10 hours of operation.

Do not operate the engine at low idle or at low speed and light load for more than 30 minutes at a time. Since unburned fuel and engine oil will adhere to the piston rings when operating at low speeds for long periods, this will interfere with proper movement of the rings and the lube oil consumption may increase. Low idle speed does not allow break-in of sliding parts.

If operating engine at low speed and light load, you must race the engine to clean the carbon from the cylinders and fuel injection 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 idle or low speed. The boat should be run at maximum speed minus 400 rpm most of the time (approximately 70% load), with a 10 minute run at maximum minus 200 - 300 rpm (approximately 80% load) every 30 minutes and a 4 - 5 minute period of operation at WOT (wide open throttle) once each 30 minutes. During this period, be sure not to operate your engine at low speed and light load for more than 30 minutes. If operating engine at low speed and light load by necessity, just after the low idle operation, be sure to race the engine.

To complete engine break-in, perform After

Initial 50 Hours maintenance procedures. See Periodic Maintenance Schedule on page 47.

PRODUCT OVERVIEW

6LY3 LDC Operation Manual

Page 17

COMPONENT IDENTIFICATION

Service Side

(1)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

0002020

(2)

Figure 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

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Non-Service Side

0002021

(4)

(1)

(3)

(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

6LY3 LDC Operation Manual

Page 19

NAMEPLATE

The engine nameplate and its typical location is shown in Figure 3. Replace 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,shaf t

Fuel stop power kW

Figure 3

PRODUCT OVERVIEW

6LY3 LDC Operation Manual

Page 20

FUNCTION OF MAJOR COMPONENTS

Name of Component Function

Fuel Filter

Removes dirt and water from the fuel. Drain the filter periodically. The filter element should be replaced periodically. See Replace the Fuel Filter Element on page

51.

Fuel Feed Pump

Pumps fuel from tank to the fuel injection pump. Equipped with built-in centrifugal vane.

Engine Oil Fill Port The fill port used to add engine lubricating oil.

Lubricating Oil Filter (at full-flow and bypass sides)

Filters fine metal fragments and carbon from the lubricating oil. Filtered lube oil is distributed to the engine’s moving parts.

Cooling Water System

There are two cooling systems: freshwater and seawater. The engine’s combustion heat is cooled by the fresh water / coolant in a closed circuit. The fresh water is cooled by seawater using heat exchanger. The seawater also cools the lube oil of engine / marine gear and also intake air through coolers in an open circuit.

Freshwater Cooler

The freshwater cooler is a heat exchanger to cool the fresh water by using seawater.

Freshwater Pump

The centrifugal water pump circulates fresh cooling water inside the engine. The fresh water pump is driven by V-belt.

Seawater Pump

The rubber impeller type pump raises seawater for cooling. Never operate it without seawater, as this will damage the impeller.

Freshwater / Coolant Fill Cap

The fill cap on the coolant tank covers the water supply port. The cap has a pressure regulating valve. When the cooling water temperature 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 consumption. Freshwater / coolant level can easily be checked and refilled in this tank.

Oil Cooler

This heat exchanger cools high temperature lube oil with seawater.

Turbocharger

The pressurized intake air feeding device: the exhaust gas turbine is rotated by the exhaust gas, and the power is used to rotate the blower. This pressurizes the intake air for sending to the cylinder.

Inter-Cooler

This heat exchanger cools the pressurized intake air from the turbocharger with seawater.

Anti-Corrosion Zinc Anode

The metal area of the seawater cooling system is prone to electrical corrosion. The anti-corrosion zinc anode is installed in the oil cooler, aftercooler, etc. to prevent this. The anti-corrosion zinc anode is itself reduced over time by electrical corrosion, so it must be replaced at fixed intervals before it is completely consumed in order to ensure that the metal area of the seawater cooling system remains fully protected.

Nameplates

Nameplates are provided on the engine and the marine gear and include the model, serial number and other data.

Starter Starter motor for the engine. Powered by the battery.

Alternator Driven by V-belt and generates electricity and charges the battery.

PRODUCT OVERVIEW

6LY3 LDC Operation Manual

Page 21

ELECTRONIC CONTROL SYSTEM (ECS)

the control equipment consists of the rocker switch panel, the display, engine interface module and the control head, which are connected by the wire harness to the engine (electronic governor and marine gear) for remote control operation.

See Yanmar Electronic Control System Operation Manual for LY3 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 – Digital Display 9 – Control Head (shift and throttle)

PRODUCT OVERVIEW

6LY3 LDC Operation Manual

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Display

Refer to the Electronic Control System Manual for 6LY3, available as a separate

volume, for details.

Display Function

Runtime Engine Data Tri-Screen (Figure 5)

WTR TEMP

X1000

RPM

PSi

2615

0 100

100 250

114 Fah

SINGLE

OIL PRES

0002023

Figure 5

This screen displays real time engine data and alarm indications.

Alarm Indicators (Figure 6)

Alarm window appears with an audible alarm when abnormal engine activity occurs.

Note: When starting 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

Alarm Log Screen (Figure 7)

Alarm Log

061803

CONTACT YANMAR DISTRIBUTOR

17:04- COM ERROR Y 025 P0120/FEB0 THROTTLE SENSOR VALUE OUT OF RANGE.

CLR

Port Eng Alarms

EXIT

0002025

Figure 7

PRODUCT OVERVIEW

6LY3 LDC Operation Manual

Page 23

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 when the engine lube oil pressure drops.

• Electric charge alarm indicator comes on when there is a charging failure.

Rocker Switch Panel

The rocker switch panel has the following functions.

1st Station Panel (Figure 8)

Start

Eng ON

OFF

Emergency

Stop

Sub throttle active

Sub throttle

0002026

Figure 8

1. To start and stop the engine:

• To start the engine, push upper half of Eng ON switch (Start).

• To stop the engine, push bottom half of Eng ON switch (OFF).

Note: The engine will take 2 to 7 seconds to stop running after the bottom 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 after using the Emergency Stop switch may be slower or more difficult than normal starting.

3. Sub throttle Control (Figure 8, (3))

In the unlikely event that the throttle

control fails, the Sub throttle indicator

light will flash and the engine speed is

controlled by the Sub throttle. Engine

speed rises when the Sub throttle knob

is turned clockwise.

• When the Sub throttle indicator flashes, turn the Sub throttle knob counterclockwise to the end and turn the knob clockwise gradually until the Sub throttle indicator turns on (steady light).

• Each engine is controlled by a dedicated Sub throttle controller.

PRODUCT OVERVIEW

6LY3 LDC Operation Manual

Page 24

2nd Station Panel - Optional (Figure 9)

Start

Eng ON

OFF

Emergency

Stop

0002027

Figure 9

1. Eng ON switch (Figure 9, (1)) is wired to

1st station panel.

2. Able to start and stop the engine from 2nd station panel

3. Emergency Stop switch is wired in series with 1st station panel (Figure 9, (2)).

Wiring Diagrams

For Instrument Panel wiring diagrams, please contact your authorized Yanmar Marine dealer or distributor, or refer to the relevant Installation Manual or Service Manual.

Control Head Shift and Throttle Functions

Use the two-lever control head (Figure 10, (4)) in the helm station for AHEAD (Figure 10, (1)), ASTERN

(Figure 10, (3)), NEUTRAL (Figure 10, (2)) and speed control in a twin

installation.

0002028

Figure 10

Use the single-lever control head (Figure 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

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 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 activates the station (used in conjunction with two or more control stations).

• SYNC Button – Pushing this button

engages / disengages the Cruise Synchronization option (if installed) when the port and starboard control head levers are set to nearly the same positions.

PRODUCT OVERVIEW

6LY3 LDC Operation Manual

Page 25

Control Head Operation

Selecting Active Station:

N N

SELECT

SYNC

N N

SELECT

SYNC

N N

SELECT

SYNC

0002030

1 32

Figure 12

1. (Figure 12, (1)) shows a typical inactive

station.

2. Press the SELECT button

(Figure 12, (2)). The button lights (grayed in Figure 12) and the station select light flashes (star around light in (Figure 12)).

3. Move the handle(s) to F (forward) or R (reverse) throttle to match the handle location of the active station (Figure 12, (3)). The corresponding handle button lights glow steady (grayed in (Figure 12, (3))) and the station select light glows steady (grayed in (Figure 12, (3))).

Engaging / Disengaging Shift Disconnect Mode:

N N

SELECT

SYNC

N N

SELECT

SYNC

N N

SELECT

SYNC

N N

SELECT

SYNC

N N

SELECT

SYNC

0002044

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 around light(s) in (Figure 13, (2)).

3. Move the handle(s) to forward or reverse throttle (Figure 13, (3)) resulting in engine rpm control without engaging marine gear.

Disengage:

1. Return the handle(s) to N (neutral) (Figure 13, (4)).

2. Press the N (neutral) button(s) (Figure 13, (5)). The neutral light(s) glow steady (Figure 13, (5)).

PRODUCT OVERVIEW

6LY3 LDC Operation Manual

Page 26

Engaging / Disengaging Split Range Throttle (SRT):

Note: Split Range Throttle is not available if the boat is equipped with the Trolling option.

The Split Range Throttle control head mode gives you greater throttle sensitivity. In Split Range Throttle (SRT), moving an engine’s control lever all the way to the “Full Forward” position will only produce the maximum percentage of wide open throttle selected in the “Features Selection” of the ECU program options. Typical Throttle Limit percentages for SRT are 5% to 50%, with 25% being the default value.

N N

SELECT

SYNC

N N

SELECT

SYNC

N N

SELECT

SYNC

0002045

Figure 14

Engage:

1. Move the engine’s lever to an in-gear idle position (Forward Idle or Reverse Idle) (Figure 14, (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 will come on (steady) to indicate that the system is in neutral. When the lever is moved back into gear, the N (neutral) lamp will resume flashing to indicate that the system is still in Split Range Throttle.

Disengage:

Return the engine lever to a Gear Idle position (Forward Idle or Reverse Idle) (Figure 14, (3)). Press the N (neutral) button next to the lever on the control head. The N (Neutral) lamp will stop flashing, indicating that the Split Range Throttle has been disengaged.

PRODUCT OVERVIEW

6LY3 LDC Operation Manual

Page 27

Engaging / Disengaging Cruise Synchronization:

N N

SELECT

SYNC

N N

SELECT

SYNC

N N

SELECT

SYNC

N N

SELECT

SYNC

N N

SELECT

SYNC

0 - 5%

0002041

1 3

Figure 15

Engage:

1. Disengage any other engine mode being used.

2. Match all engine shift and throttle settings by moving the active port and starboard control head levers to within 5% of each other (Figure 15, (1)) and press the SYNC button (Figure 15, (4)) on the control head. The sync lamp flashes if the handles are not within 5% of each other (Figure 15, (3)). The sync lamp will stop flashing and remain continuously lit (Figure 15, (4)) when the levers 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 electricity to arbitrary direct current voltage.

133

96.5

(1)

(2)

(3)

(4)

024522-00X

1 – 6LY3-LDC Electric Control

System Harness Side 2 – Input Line 3 – Output Line 4 – Relay Harness

Items

Product Name Switched-mode

DC-DC converter

Model HADC-20

Input voltage DC18 - 32 V

Output voltage DC13.8V (±5%)

Output current 15A

Operating temperature -10 - 60°C

Storage temperature -40 - 85°C

PRODUCT OVERVIEW

6LY3 LDC Operation Manual

Page 28

Outline Drawing

1500

(3)

(2)

(5) (6)

(4)

(1)

18~32V

024523-00X

HADC-20

1 – Input Electric Cable 2 – 18-32V (Blue) + 3 – Ground (Black) -

4 – Ground 5 – Fuse Holder (MF-506) 6 – LA8Ø Terminal

Fuse Replacement Procedure and Checking the Normal Operation

Check the normal operation when the instrument panel 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

6LY3 LDC Operation Manual

Page 29

BEFORE YOU OPERATE

This section of the Operation Manual describes the diesel fuel, engine oil, and engine coolant specifications and how to replenish them. It also describes the daily engine checkout.

Before performing any operations within this section, review the Safety section on page 4.

DIESEL FUEL

DANGER! Diesel fuel is flammable and

explosive under certain conditions. Refer to Fire and Explosion 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-D, No. 1-D, ASTM D975

USA

EN590:96 European Union

ISO 8217 DMX International

BS 2869-A1 or A2 United Kingdom

JIS K2204 Grade No. 2 Japan

6LY3 LDC Operation Manual

Page 30

Bio-Diesel Fuels

Yanmar approves the use of biodiesel fuels that do not exceed a blend of 5% nonmineral oil based fuel with 95% standard diesel fuel. Such biodiesel fuels are known in the marketplace as B5 biodiesel fuels. B5 biodiesel fuel can reduce particulate matter and the emission of “greenhouse” gases compared to standard diesel fuel.

CAUTION! If the B5 biodiesel fuel used does not meet the approved specifications, it will cause abnormal wear of injectors, reduce the life of the engine and it may affect the warranty coverage of your engine.

B5 diesel fuels must meet certain specifications

The biodiesel fuels must meet the minimum specifications for the country in which they are used:

• In Europe, biodiesel fuels must comply with the European Standard EN14214.

• In the United States, biodiesel fuels must comply with the American Standard ASTM D-6751.

Biodiesel should be purchased only from recognized and authorized diesel fuel suppliers.

Precautions and concerns regarding the use of bio-fuels:

• Biodiesel fuels have a higher content of methyl-esters, which may deteriorate certain metal, 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 injection nozzle spray atomization.

• Biodiesel may have adverse effects on some elastomers (seal materials) and may result in fuel leakage and dilution of the engine lubricating oil.

• Even biodiesel fuels that comply with a suitable standard as delivered, will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system, and / or fuel storage containers, may be necessary.

• The use of biodiesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers, or biodiesel fuels that have degraded as per the precautions and concerns above, may affect the warranty coverage of your engine.

BEFORE YOU OPERATE

6LY3 LDC Operation Manual

Page 31

Additional Technical Fuel Requirements

• The fuel cetane number should be equal to 45 or higher.

• The sulfur content must not exceed 0.5% by volume. Less than 0.05% is preferred.

• NEVER mix kerosene, used engine oil or residual fuels with the diesel fuel.

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

• Keep the fuel tank and fuel-handling equipment clean at all times.

• 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.

• Do not use Biocide.

• Do not use kerosene or residual fuels.

Handling of Diesel Fuel

1. Water and dust in the fuel may cause

engine failure. When fuel 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

Install the lines between the fuel tank and the fuel injection pump.

Be sure to install a drain cock (Figure 2, (5)) at the bottom of the fuel tank to remove water and contaminants.

Install a fuel filter / water separator (Figure 2, (2)) and a fuel filter between the fuel tank and the fuel injection pump.

0002050

(1)

(4)

(5)

(7)

(8)

(9)

(10)

(2)

(3)

(6)

Figure 2

1 – Fuel Priming Pump 2 – Fuel Feed Pump 3 – Fuel Filter / Water Separator 4 – Fuel Return Line 5 – Fuel Tank 6 – Fuel Tank Drain Cock 7 – Approximately 50 mm (1.95 in.) 8 – Fuel Shutoff Valve 9 – Less Than 500 mm (19.68 in.) 10–To Fuel Injection Pump

BEFORE YOU OPERATE

6LY3 LDC Operation Manual

Page 32

Filling the Fuel Tank

DANGER! NEVER refuel with the engine

running. Refer to Fire and Explosion Hazard on page 5.

1. Clean the area around the fuel cap.

2. Remove the fuel cap from the fuel tank.

3. Fill the tank with clean fuel free of oil and

dirt. NOTICE: Hold the hose nozzle firmly

against the filler port while filling. This prevents static electricity buildup which could cause sparks and ignite fuel vapors.

4. Stop fueling when gauge shows fuel tank

is full. NOTICE: NEVER overfill the fuel

tank.

5. Replace the fuel cap and hand-tighten. Over-tightening the fuel cap will damage it.

Bleeding the Fuel System

The engine has an automatic air bleed system. Bleeding the fuel system is not required for normal engine operation.

The fuel system needs 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

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.

NOTICE: NEVER use the starter motor to

crank the engine to bleed the fuel system. This may cause the starter motor to overheat and damage the coils, pinion and / or ring gear.

BEFORE YOU OPERATE

6LY3 LDC Operation Manual

Page 33

ENGINE OIL

NOTICE: Only use the engine oil specified. Other engine oils may affect warranty coverage, cause internal engine components to seize and / or shorten engine life. NEVER mix different types of engine oil. This may adversely affect the lubricating properties of the engine oil.

Engine Oil Specifications

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

Service Categories

• API Service Categories CD or higher

• ACEA Service Categories E-3, E-4 and E-5

• JASO Service Category DH-1

Definitions

• API Classification (American Petroleum 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 the ambient temperature where the engine is being operated. See the SAE Service Grade Viscosity Chart (Figure 3).

• Yanmar does not recommend the use of engine oil “additives.”

-4°F 14°F 32°F 50°F 68°F 86°F 104°F (-20°C) (-10°C) (0°C) (10°C) (20°C) (30°C) (40°C)

SAE 10W-30

SAE 15W-40

0000005

Figure 3

BEFORE YOU OPERATE

6LY3 LDC Operation Manual

Page 34

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).

Engine Oil Viscosity

SAE 15W40 is the recommended oil viscosity.

Checking Engine Oil

1. Make sure engine is level.

2. Remove dipstick (Figure 4, (3)) and

wipe with clean cloth.

3. Fully reinsert dipstick.

4. Remove dipstick. The oil level should be

between upper (Figure 4, (4)) and lower (Figure 4, (5)) lines on the dipstick.

5. Fully reinsert dipstick.

0002051

Figure 4

Adding Engine Oil

1. NOTICE: Prevent dirt and debris from contaminating engine oil. Carefully clean the dipstick, filler port cap and the surrounding 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: 8 L (8.5 quarts)

• “Full” means the oil amount at the upper

limit (Figure 4, (4)) on a dipstick.

• “Effective” means the difference

between oil amount at upper limit and that at lower limit (Figure 4, (5)).

NOTICE: ALWAYS keep the oil level

between the upper and lower lines on the oil cap / dipstick.

3. Hand-tighten the filler port

(Figure 4, (2)) cap securely.

Selection of Marine Gear Oil

Refer to the instruction book for each marine gear.

BEFORE YOU OPERATE

6LY3 LDC Operation Manual

Page 35

ENGINE COOLANT

Use a Long Life Coolant (LLC) that meets or exceeds the following guidelines and specifications:

Note: In the U.S., LLC is required for the warranty to be valid.

• ASTM D3306, D4985 (US)

• JIS K-2234 (Japan)

• SAE J814C, J1941, J1034 or J2036 (International)

NOTICE: Following the manufacturer’s

recommendations, use a proper LLC which will not have any adverse effects on the materials (cast iron, aluminum, copper, etc.) of the engine’s cooling system. See Engine Coolant Specifications on page 33.

ALWAYS use the mixing ratios specified by the antifreeze manufacturer for the temperature range.

NOTICE: ALWAYS add LLC to soft water –

especially when operating in cold weather. NEVER use hard water. Water should be clean and free from sludge or particles. 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. Excessive use of antifreeze also lowers the cooling efficiency of the engine. NEVER mix different types or brands of LLC, as a harmful sludge may form. Mixing different brands of antifreeze may cause chemical reactions, and may make the antifreeze useless or cause engine problems.

Replace the engine coolant periodically, according to the maintenance section in this Operation Manual.

Remove scale from the cooling system periodically by flushing the system.

BEFORE YOU OPERATE

6LY3 LDC Operation Manual

Page 36

Filling Heat Exchanger with Engine Coolant

This procedure is for filling the heat exchanger for the first time or refilling it after it is flushed. Note that a typical heat exchanger is shown (Figure 5).

1. Close the four water drain cocks / plugs (two for engine coolant and two for seawater).

Note: The drain cocks are opened before shipping from the production plant.

0002052

Figure 5

1 – Freshwater Drain Cock 2 – Seawater Drain Cock

0006456

Figure 6

1 – Fresh Water Pump 2 – Coolant Tank (Heat Exchanger) 3 – Seawater Drain Cock 4 – Freshwater Drain Cock 5 – Seawater Pump

2. Remove the fill cap (Figure 7, (1)) on the heat exchanger (Figure 7, (3)) by turning the cap counterclockwise 1/3 of a turn.

WARNING! NEVER remove 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

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 port.

4. After filling the heat exchanger, replace fill cap and tighten it firmly (Figure 7, (1)). Failure to do so will cause coolant leakage. To replace the cap, align the tabs (Figure 7, (2)) on the bottom of the cap with the notches on the filler port and turn clockwise 1/3 of a turn.WARNING! ALWAYS tighten the

coolant tank cap securely after checking the coolant tank. Steam can spray out during engine operation if the cap is loose.

BEFORE YOU OPERATE

6LY3 LDC Operation Manual

Page 37

5. Remove the coolant recovery tank cap

(Figure 8, (2)) and fill with coolant mix to the lower limit (Figure 8, (4)). Replace cap. Never fill to the upper limit (Figure 8, (3)). Coolant recovery tank capacity: 0.8 L (1.7 pints)

6. Check the rubber hose (Figure 8, (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 the connection, an excessive amount of coolant will be lost.

0002054

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 coolant.

BEFORE YOU OPERATE

6LY3 LDC Operation Manual

Page 38

This Page Intentionally Left Blank

BEFORE YOU OPERATE

6LY3 LDC Operation Manual

Page 39

ENGINE OPERATION

This section of the Operation Manual describes the diesel fuel, engine oil and engine coolant specifications and how to replenish them. It also describes the daily engine checkout.

Before performing any operations within this section, review the Safety section on page 4.

WARNING

Fire and Explosion Hazard

NEVER jump-start the engine. Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion.

ONLY use the key switch to start the engine.

Sudden Movement 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 windows, vents or other means of ventilation if the engine is operating in an

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

6LY3 LDC Operation Manual

Page 40

CAUTION

• If the vessel is equipped with a water lift (water lock) muffler, excessive cranking could cause seawater to enter the cylinders and damage the engine. If the engine does not start after cranking 15 seconds, close the thru-hull water intake valve to avoid filling the muffler with water. Crank for 10 seconds at a time until the engine starts. When the engine does start, stop the engine immediately and turn the switch to the OFF position.

• Be sure to re-open the seacock and restart the engine. Operate the engine normally.

NOTICE

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

If the alarm window with audible alarm fails to display and go out about 3 seconds later when the ignition switch is 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 (+104F) or below -16C (+5F).

• If the ambient temperature exceeds +40C (+104F), the engine may overheat and cause the engine oil to break down.

• If the ambient temperature is below -16C (+5F), rubber components such as gaskets and seals will harden, causing premature engine wear and damage.

• Contact your authorized Yanmar Marine engine dealer or distributor if the engine will be operated outside of this standard temperature range.

NEVER engage the starter motor while the engine is running. Damage to the starter motor pinion and / or ring gear will result.

ENGINE OPERATION

6LY3 LDC Operation Manual

Page 41

STARTING THE ENGINE

Before Starting the Engine

1. Open the seacock.

2. Open the fuel tank cock.

3. Set the control lever on the control head

(Figure 1, (2)) in N (neutral) (Figure 1, (1)) position.

0002056

Figure 1

4. Turn on the battery switch and the start-

up / version screen (Figure 2) pops up on the display. Then, the screen will change to the engine data display mode.

i5601E

LY3

PORT

Multi-Function Display

Electronic Controls

Ver 3.00P

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.

WTR TEMP

X1000

RPM

PSi

2615

0 100

100 250

114 Fah

SINGLE

OIL PRES

0002060

Figure 4

To Start the Engine

To start the engine, press Start (upper half) of Eng ON switch (Figure 3, (1)).

NOTICE: Never hold the key in the start

position for longer than 15 seconds or the starter motor will overheat.

ENGINE OPERATION

6LY3 LDC Operation Manual

Page 42

If the Engine Fails to Start

Before pressing the Start switch again, confirm that the engine has stopped completely. If the engine is restarted before it has completely stopped, the starter motor pinion gear will be damaged.

Note: Hold the key switch for a maximum of 15 seconds in the Start position. If the engine does not start the first time, turn the key switch OFF and wait for about 15 seconds before trying again. After the engine has started, do not turn the key switch OFF. (It should remain on.)

NOTICE: If the vessel is equipped with a water lift (water lock) muffler, excessive cranking could cause seawater to enter the cylinders and damage the engine. If the engine does not start after cranking for 15 seconds, close the thru-hull water intake valve to avoid filling the muffler with water. Crank for 10 seconds at a time until the engine starts. When the engine does start, stop the engine immediately and turn the key switch to the OFF position. 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 problems, keep the engine at low speed to send engine oil to all parts of the engine.

5. Check that sufficient seawater is discharged from the seawater / exhaust 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 in air due to a loose joint?

CAUTION! The engine will seize if it is operated when seawater discharge is too small or if load is applied without any warming up operation.

ENGINE OPERATION

6LY3 LDC Operation Manual

Page 43

Shifting

WARNING! SUDDEN MOVEMENT

HAZARD! The boat will start to move when the marine gear is engaged:

• Ensure the boat is clear of all obstacles forward and aft.

• Quickly shift to the FORWARD position then back to the NEUTRAL position.

• Observe whether the boat moves in the direction you expect.

Neutral

Be sure to set the control lever at N (neutral) position (Figure 5, (1)).

Note: Clutch operation or the use of trolling during high speed will cause internal parts of the clutch to break or to wear excessively.

1. Before using the marine gear, be sure to

move the control lever (throttle) to a low idle position (the detent position). Then, move the control lever slowly to a higher speed position after completing clutch engagement.

2. When changing between 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.

-N-

SEL

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 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. The marine gear will shift into REVERSE. The engine will remain at idle. Pulling further on the control lever will increase the rpm up to a maximum of wide open throttle (WOT).

ENGINE OPERATION

6LY3 LDC Operation Manual

Page 44

CAUTIONS DURING OPERATION

Note: Engine trouble can arise if the engine is operated for a long time under overloaded conditions with the control lever in the full throttle position (maximum engine speed position), exceeding the continuous rated output engine speed. Operate the engine at about 100 rpm lower than the full throttle engine speed.

Note: If the engine is in the first 50 hours of operation, see New Engine Break-In on page 9.

Always be on the lookout for problems during engine operation.

Pay particular attention to the following:

1. Is sufficient seawater being discharged from the exhaust and seawater outlet pipe? If the discharge is small, stop the engine immediately; identify the cause and repair.

2. Is the exhaust color normal? The continuous emission of black exhaust smoke indicates engine overloading. This shortens the engine’s life and should be avoided.

3. Are there abnormal vibrations or noise?

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 vibrations. Avoid operation in this speed range. If you hear any abnormal sounds, stop the engine and inspect.

4. Alarm buzzer sounds during operation

. NOTICE: 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 continue to operate the engine.

5. Is there water, oil or fuel leakage, or are there any loose bolts? Check the engine room periodically for any problems.

6. Is there sufficient diesel fuel in the diesel fuel tank? Replenish diesel fuel before leaving the dock to avoid running out of fuel during operation.

ENGINE OPERATION

6LY3 LDC Operation Manual

Page 45

7. When operating the engine at low speed for long periods of time, race the engine once every 2 hours.

Note: Racing the engine: With the gear in NEUTRAL, accelerate from the low speed position to the high speed position and repeat this process about 5 times. 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 life of the engine . NOTICE: NEVER turn off the battery

switch (if equipped) or short the battery cables during operation. Damage to the electric system will result.

ENGINE OPERATION

6LY3 LDC Operation Manual

Page 46

SHUTTING DOWN THE ENGINE

Stop the engine in accordance with the following procedures:

Normal Shutdown

1. Return the control lever to NEUTRAL position. (The N light turns on.)

2. Cool the engine down at low speed (below 1000 rpm) for about 5 minutes.

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 that operate at high temperatures, such as the turbocharger (if equipped) and exhaust system, to cool slightly before the engine itself is shut down.

3. Push OFF (bottom half) of Eng ON switch (Figure 6, (3)). The engine shuts down within 2 to 7 seconds normally. The regular engine shutdown takes time because the controller is adjusted in the fuel injection timing to the most suitable position for the next start.

4. Turn the battery switch off.

5. Close the fuel 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 shutdown. Use this switch only when stopping the engine suddenly in an emergency.

Start

Eng ON

OFF

Emergency

Stop

Sub throttle active

Sub throttle

(2)

0002062

(3)

(1)

Figure 6

Push the upper part of the Emergency Stop switch (Figure 6, (1)) on the right 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. NOTICE: Use this switch only in an

emergency. Under normal circumstances, use the OFF, Eng ON, Start switch (Figure 6, (3)) to stop the engine.

ENGINE OPERATION

6LY3 LDC Operation Manual

Page 47

Note: Restarting the engine after using the emergency stop may be slower or more difficult than normal starting.

Mechanical Emergency Stop:

If for some reason you can’t stop the engine by the stop switch on the panel, push the stop lever (Figure 7, (1)) towards the front of the engine (Figure 7, (2)) to shut down the engine in the engine room. WARNING!

SEVER HAZARD. ALWAYS keep hands, body parts and loose fitting clothes away from moving / rotating parts such as the flywheel or PTO shaft. When

pushing the stop lever to the front side, the trouble indication of the governor pops up 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 contains enough coolant.

See Filling Heat Exchanger with Engine Coolant on page 30.

• If there is a risk of freezing, drain the seawater system. See Before You Place

the Engine in Long-Term Storage on page

69.

• At temperatures below 0C (32F), drain seawater system and connect the engine heater (if equipped).

ENGINE OPERATION

6LY3 LDC Operation Manual

Page 48

This Page Intentionally Left Blank

ENGINE OPERATION

6LY3 LDC Operation Manual

Page 49

PERIODIC MAINTENANCE

This section of the Operation Manual describes the procedures for proper care and maintenance of the engine.

Before performing any maintenance procedures within this section, read the following safety information and review the Safety section on page 4.

SAFETY PRECAUTIONS

WARNING

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 sufficient capacity to lift the marine engine.

6LY3 LDC Operation Manual

Page 50

WARNING

Welding Hazard

• 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.

• 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 completed, reconnect the leads to the alternator prior to reconnecting the batteries.

Exhaust Hazard

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

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

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 for the electrical system.

NOTICE

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.

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. Always use Yanmar genuine replacement parts.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 51

PRECAUTIONS

The Importance of Periodic Maintenance

Engine deterioration and wear occurs in proportion to length of time the engine has been in service and the conditions the engine is subject to during operation. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor machine performance and helps extend the life of the engine.

Performing Periodic Maintenance

WARNING! NEVER block windows,

vents, or other means of ventilation if the engine is operating in an enclosed area. All internal combustion engines create carbon monoxide gas during operation. Accumulation of this gas within an enclosure could cause illness or even death. Make sure that all connections are tightened to specifications after repair is made to the exhaust system. Failure to comply could result in death or serious injury.

The Importance of Daily Checks

Periodic Maintenance Schedules assume that the daily checks are performed on a regular basis. Make it a habit of performing daily checks before the start of each operating day. See Daily Checks on page

50.

Keep a Log of Engine Hours and Daily Checks

Keep a log of the number of 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 periodic maintenance will shorten the life of the engine and may void the warranty.

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 professional service technicians have the expertise and skills to help you with any maintenance or service related procedures you need help with.

Required EPA Maintenance - USA Only

To maintain optimum engine performance and compliance with the Environmental Protection Agency (EPA) Regulations, it is essential that you follow the Periodic

Maintenance Schedule on page 47 and Periodic Maintenance Procedures on page

50.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 52

EPA Installation Requirements USA Only

The following are the installation requirements for the EPA. Unless these requirements are met, the exhaust gas emissions will not be within the limits specified by the EPA.

See Conditions to Ensure Compliance with EPA Emission Standards on page 63 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.

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

Tightening Torque

N·m 11.0 ± 1.0 26.0 ± 3.0 50.0 ± 5.0

90.0 ±

10.0

140.0 ± 10.0 230.0 ± 10.0

kgf-m 1.1 ± 0.1 2.7 ± 0.3 5.1 ± 0.5 9.2 ± 1.0 14.3 ± 1.0 23.5 ± 1.0

lb-ft 8.0 ± 0.7 19.0 ± 2.1 37 ± 3.6 66.0 ± 7.2 103 ± 7.2 170 ± 7.2

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 53

PERIODIC MAINTENANCE SCHEDULE

Daily and periodic maintenance are important to keep the engine in its best operating condition. The following is a summary of inspection and servicing items by inspection interval. Periodic maintenance intervals should vary depending on the uses, loads, fuels and lubricating oils used, and handling conditions, and are hard to establish definitively. The following should be treated as a general guide only. Periodic

Maintenance Procedures on page 50

gives a detailed explanation of which parts must be inspected and the procedure for doing so for each interval.

CAUTION! Establish a periodic maintenance plan according to the engine application and make sure to perform the required periodic maintenance at the intervals indicated. Failure to follow these guidelines will impair the engine’s safety and performance characteristics, shorten the engine’s life and may affect the warranty coverage on your engine. See your 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

comes

first

Every 1000

hours or

one year,

whichever

comes first

Every 2000

hours or two years, whichever

comes first

Whole Visual inspection of engine exterior

◯

Fuel System Check the fuel level and refill if

necessary

◯

Drain the fuel tank

◯

Drain the fuel filter and fuel / water separator

◯

Replace the fuel filter element

◊

(1st time)

◊

Check the fuel injector spray pattern *

●

(1st time)

●

Overhaul and check fuel feed pump ●

Replace rubber fuel hoses Replace every 2 years or every 2000 hours, whichever comes first.

Lubricating System

Check the engine oil level

Crankcase

◯

Replace the engine oil

Crankcase

◊

(1st time)

◊

Replace the oil filter element

◊

(1st time)

◊

Clean engine oil cooler ●

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 54

◯: 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

comes

first

Every 1000

hours or

one year,

whichever

comes first

Every 2000

hours or two years, whichever

comes first

Cooling System Seawater outlet ◯ During Op-

eration

Check coolant level

◯

Check the seawater pump impeller

◯

◊

Replace the engine coolant Every year. When Long Life Coolant (LLC) is used, replace every two years.

See Engine Coolant on page 29.

Clean and check the seawater passages

●

Clean seawater and engine cooling system

●

Replace zinc anode ◊

Air Intake and Exhaust System

Clean the air intake silencer

◯

Clean the exhaust / water mixing elbow

◯

◊

Clean the turbocharger blower

●

Flush aftercooler ●

Electrical System

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 fuel, engine oil and engine coolant

◯

After Starting

Tighten all major nuts and bolts ●

Adjust intake / exhaust valve clearance

●

(1st time)

●

Miscellane- ous Items

Check the electronic control system operation

◯

(1st time)

Adjust the propeller shaft alignment

●

(1st time)

●

Check / replace flexible engine mounts

◯

◊

* For EPA requirements, See EPA Requirements on page 62.

Note: These procedures are considered normal maintenance and are performed at the owner’s expense.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 55

Inspection and Maintenance of EPA Emission-Related Parts

Action Interval

Clean the fuel injection nozzle 1500 hours

Check the fuel injection nozzle pressure and spray pattern

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

Page 56

PERIODIC MAINTENANCE PROCEDURES

WARNING! ALWAYS wear personal

protective equipment. Refer to Exposure Hazard on page 6.

Daily Checks

Before you head out for the day, make sure the Yanmar engine is in good operating condition. CAUTION! It is important to

perform the daily checks as listed in this Operation Manual. Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor engine performance and helps extend the life of the engine.

Make sure you check the following items.

Visual Checks

1. Check for engine oil leaks.

2. Check for fuel leaks. WARNING! Avoid

skin contact with the 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 any damage.

3. Check for engine coolant leaks.

4. Check for damaged or missing parts.

5. Check for loose, missing or damaged fasteners.

6. Check the electrical harnesses for cracks, abrasions and damaged or corroded connectors.

7. Check hoses for cracks, abrasions and damaged, loose 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 Tank on page

57.

CAUTION! If any problem is noted during the visual check, the necessary corrective action should be taken before operating the engine.

Check Diesel Fuel, Engine Oil and Engine Coolant Levels

Follow the procedures in Diesel Fuel on page 23, Engine Oil on page 27 and Engine Coolant on page 29 to check these levels.

Checking and Refilling Marine Gear Oil

Refer to the Operation Manual for the marine gear.

Checking the Control Head

Be sure to check that the control lever moves smoothly before use. If it is hard to operate, see your authorized Yanmar Marine 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 16.

Preparing Fuel, Oil and Coolant in Reserve

Prepare sufficient fuel for the day’s operation. Always store engine oil and coolant in reserve (for at least one refill) onboard, to be ready for emergencies.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 57

After Initial 50 Hours of Operation

Perform the following maintenance after the initial 50 hours of operation.

• Replace Fuel Filter Element

• Replace Engine Oil and Engine Oil

Filter

• Check Electronic Control System Operation

• Adjust Propeller Shaft Alignment

Replace the Fuel Filter Element

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 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 removing any fuel system component.

When the 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)).

0002078A

Figure 1

4. Check for fuel leaks. WARNING! Avoid

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 58

Replace Engine Oil and Engine Oil Filter

The engine oil on a new engine becomes contaminated from the initial break-in of internal parts. It is very important that the initial oil change is performed as scheduled.

It is easiest and most effective to drain the engine oil after operation while the engine is still warm. WARNING! If the engine oil

must be drained while it is still hot, stay clear of the hot engine oil to avoid being burned.

1. Turn the engine off.

2. NOTICE: Prevent dirt and debris from

contaminating engine oil. Carefully clean the dipstick and the surrounding area before removing the dipstick. Remove the engine oil dipstick.

Attach the oil drain pump and pump out the oil. For easier draining, remove the engine oil fill cap (Figure 2, (2)) (yellow) at the top of the rocker arm cover. Dispose of used oil properly. NOTICE: 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. Turn the full-flow oil filter an additional 3/4 of a turn clockwise with the filter wrench.

0002073

Figure 2

6. Fill with new engine oil. See Adding Engine Oil on page 28. NOTICE: 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.

7. Perform a trial run and check for oil leaks.

8. 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! Be careful not to get any oil on the V-belt. Oil on the belt causes slipping and stretching. Replace the belt if it is damaged.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 59

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 misalignment between the engine and the propeller shaft.

Check for any unusual noise and vibration in the engine / boat hull, while increasing and decreasing the engine speed gradually.

If there is unusual noise and / or vibration, this maintenance requires specialized knowledge and techniques. See your authorized Yanmar Marine dealer or distributor to adjust the propeller shaft alignment.

Every 50 Hours of Operation

Perform the following maintenance every 50 hours or one month of operation, whichever 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

CAUTION! If the fuel filter / water separator is positioned higher than the fuel level 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.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 60

Drain the Fuel Filter

0002074A

Figure 3

1. Close the fuel tank cock.

2. Loosen the drain plug (Figure 3, (1)).

Drain off any water and dirt collected inside. Dispose of the collected water and dirt properly. NOTICE: ALWAYS be

environmentally responsible.

Drain the Fuel Filter / Water Separator

Element

0002075A

Figure 4

1. Close the fuel tank drain cock.

2. Loosen the drain plug (Figure 4, (1)) at

the bottom of the fuel filter / water separator and drain off any water and dirt.

3. Remove the center bolt (Figure 4, (2))

to disassemble the fuel filter / water separator. Clean the element (Figure 4, (3)) inside with clean fuel.

4. When a fuel filter or fuel 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

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 61

Check the Battery

WARNING! Batteries contain sulfuric

acid. NEVER allow battery fluid to come in contact with clothing, skin or eyes. Severe burns could result. ALWAYS wear safety goggles and protective clothing when servicing the battery. If battery fluid contacts the eyes and / or skin, immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment.

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

NOTICE: NEVER operate with insufficient battery electrolyte. Operating with insufficient electrolyte will destroy the battery.

NOTICE: Battery fluid tends to evaporate in high temperatures, especially in summer. In such conditions, inspect the battery earlier than specified.

(1)

(2)

(3)

0002388

Figure 5

1. Do not operate engine if battery has insufficient battery fluid, as the battery will be 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. If the starter rpm is too low and the engine cannot be started, measure the specific gravity of the battery with a hydrometer. When the specific gravity of the fluid is over 1.27 at 20°C (68°F), it is fully charged. Fluid with a specific gravity 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 authorized Yanmar Marine dealer or distributor.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 62

Adjust Alternator V-Belt Tension

When there is not enough tension in the Vbelt, it will slip and the freshwater pump will fail to supply coolant. Engine overheating and seizure will result.

When there is too much tension in the V-belt, the belt will become damaged more quickly and the freshwater pump bearing may be damaged.

WARNING! Perform this check with engine off and key removed to avoid contact with moving parts.

NOTICE: NEVER get any oil on the belt(s). Oil on the belt causes slipping and stretching. Replace the belt if it is damaged.

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 tension.

3. If the V-belt is damaged or worn, replace it. Loosen the adjuster bolt

(Figure 6, (2)) and move the alternator (Figure 6, (3)). Remove belt from

pulleys.

4. Install new belt per routing (Figure 6) and adjust the tension as shown in Step

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 63

Every 250 Hours of Operation

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 Zinc 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.

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 page 51.

Replace the Engine Oil (Crankcase)

See Replace Engine Oil and Engine Oil Filter on page 52.

Replace the Engine Oil Filter Element

See Replace Engine Oil and Engine Oil Filter on page 52.

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 flashlight and inspect.

3. If any of the following problems are found, disassembly and maintenance are necessary:

• Impeller blades are cracked or nicked.

• Edges or surfaces of the blades are

marred or scratched.

• Wear plate is damaged.

4. If no damage is found when inspecting the inside of the pump, reassemble the side cover.

Note: Fit the O-ring to the groove on the joint face before replacing the side cover.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 64

If a large amount of water leaks continuously from the water drain pipe beneath the seawater pump during operation, disassembly and maintenance (replacement of the lip seal) are necessary.

When disassembly and maintenance of the seawater pump are necessary, see your Yanmar dealer or distributor.

Note: The seawater pump turns in the direction as shown (Figure 7) and the impeller must be installed to run in this direction. If the impeller has been removed for any reason and must be reassembled, be very careful not to install it in the wrong direction. Additionally, if the engine is being turned manually, be careful to turn it in the correct direction. Incorrect turning will twist the impeller and damage it.

0002080

Figure 7

Replace the Zinc Anode

The timing for 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 cooling system will occur and water leakage or parts breakage will result.

The label (Figure 8) is stamped on the plugs which have the zinc anode.

ZINC

0002081

Figure 8

Be sure to close the seacock before removing the plug to replace the zinc anode.

Clean the Air Intake Silencer

Disassemble the intake silencer and clean the inside thoroughly.

1. Take off the clamp and remove the muffler.

2. Clean the element with a neutral detergent.

3. Reassemble after the muffler is completely dry.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 65

Clean the Exhaust / Water Mixing Elbow

The mixing elbow is attached to the turbocharger. The exhaust gas is mixed with seawater in the mixing elbow.

1. Clean dirt and scale out of the exhaust gas passage and seawater way in the mixing elbow.

2. Repair the crack or damage of the mixing elbow by welding, or replace if necessary.

3. Inspect the gasket and replace if necessary.

Clean the Turbocharger Blower

Contamination of the turbocharger blower causes blower revolutions to drop and engine output to fall.

If a drop of engine output is noted (by about 10%), clean the blower. This should only be done by a trained and qualified technician. See your authorized Yanmar Marine dealer or distributor to clean the turbocharger blower.

Flush the Aftercooler

Contamination of the aftercooler causes the engine output to fall.

If a drop of engine output is noted (by about 10%), flush and 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 a long period of usage, the major nuts and bolts of the engine may loosen. Tighten the major nuts and bolts to the standard tightening torques. This inspection requires specialized knowledge and techniques. 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 misalignment of the propeller shaft.

1. Check if the rubber is cracked. If necessary, replace the flexible mount.

2. Check for abnormal noise or vibration while engine is running. If necessary, replace the flexible mount.

CAUTION! NEVER get any engine oil or diesel fuel oil on the flexible rubber mount. Oil makes rubber deteriorate.

Replace Engine Coolant

CAUTION! Wear eye protection and

rubber gloves when you handle engine coolant. If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water.

Cooling performance drops when coolant is contaminated with rust and scale. The coolant must be replaced periodically because its properties deteriorate over time.

To drain the engine coolant, open the freshwater drain cocks (two places).

See Engine Coolant on page 29 for coolant specifications.

NOTICE: NEVER mix different types and /

or colors of coolants.

Discard old coolant in an approved manner according to environmental laws.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 66

Every 500 Hours of Operation

Perform the following maintenance every 500 hours or two years of operation, whichever comes first.

• Replace Seawater Pump Impeller

• Adjust the Propeller Shaft Alignment

• Check Alternator Belt Tension

• Replace the Exhaust / Water Mixing

Elbow

• Adjust the No-Load Minimum Speed

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 of use. This leads to a drop in vibration absorption performance, and also causes centering misalignment of the propeller shaft.

This maintenance requires specialized knowledge and techniques. See your authorized Yanmar Marine dealer or distributor to adjust the propeller shaft alignment.

Check Alternator Belt Tension

Check the alternator belt tension. See Adjust Alternator V-Belt Tension on page

56.

Replace the Exhaust / Water Mixing Elbow

The exhaust / water mixing elbow must be replaced at 500 hours or 2 years, even if no damage is found. See your authorized 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

• Clean and Check the Water Passages

• Replace Alternator Belt

• Adjust Intake / Exhaust Valve

Clearance

• Replace Flexible Engine Mounts

Check the Fuel Injector Spray Pattern

Adjustment is necessary to obtain the 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.

Clean and Check the Seawater Passages

When it is used for a long time, cleaning the seawater passages is periodically necessary because trash, scales, rust and other deposits or debris collect in the seawater passages and the cooling performance declines.

This maintenance requires specialized knowledge. See your authorized Yanmar Marine dealer or distributor to clean and check the water passages.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 67

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 56.

Adjust Intake / Exhaust Valve Clearance

Proper adjustment is necessary to maintain the correct timing for opening and closing the valves. Improper adjustment will cause the engine to run noisily, resulting in poor engine performance and engine damage. See your authorized Yanmar Marine dealer or distributor to adjust the intake / exhaust valve clearance.

Replace Flexible Engine Mounts

Be sure to replace the Yanmar flexible engine mounts every 1000 hours or 4 years, whichever comes first.

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

Fuel feed pump must be overhauled and checked to ensure optimal engine performance.

This maintenance requires specialized knowledge. See your authorized Yanmar Marine dealer or distributor to overhaul and check the fuel feed pump.

Clean Engine Oil Cooler

Rust and scale are deposited inside the seawater system during long use. These deposits lower cooling performance, so it is necessary to clean and maintain the engine oil cooler.

See your authorized Yanmar Marine dealer or distributor to clean the engine oil cooler.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 68

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 Coolant System Parts:

Seawater pump, engine oil cooler, aftercooler, freshwater pump, freshwater cooler, thermostat, etc.

See your authorized Yanmar Marine dealer or distributor to clean the seawater and engine 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 (emission control label and light duty commercial engine label) attached.

The labels are attached to the top of the electronic control unit (ECU) cover plate (Figure 9).

0006536

(119578-07701)

Figure 9

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 69

Conditions to Ensure Compliance with EPA Emission Standards

This product is an EPA-approved engine.

The following are the conditions that must be met in order to ensure that the emissions during operation meet the EPA standards:

1. Ambient temperature: -20 to 40°C (-4 to 104°F)

2. Relative humidity: 80% 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 or

higher

Be sure to perform inspections as outlined in Periodic Maintenance Procedures on page 50 and keep a record of the results.

Pay particular attention to these important points:

• Replacing the engine oil

• Replacing the lube oil filter

• 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

Inspection and Maintenance of EPA Emission-Related Parts section are covered in Periodic Maintenance Schedule on page

47.

This maintenance must be performed to keep the emission values of your engine in the standard range 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 Warranty

- USA Only on page 77.

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 70

This Page Intentionally Left Blank

PERIODIC MAINTENANCE

6LY3 LDC Operation Manual

Page 71

TROUBLESHOOTING

Before performing any troubleshooting procedures within this section, review the Safety section on page 4.

If a problem occurs, stop the engine immediately. Refer to the Symptom column in the Troubleshooting Chart to identify the problem.

CAUTION! If any indicator fails to illuminate when the key switch is in the ON position, see your authorized Yanmar Marine dealer or distributor for service before operating the engine.

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.

TROUBLESHOOTING AFTER STARTING

Just after the engine has 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 noise?

• Depending on the hull structure, engine and hull resonance may suddenly increase at certain engine speed ranges, causing heavy vibrations. Avoid operation in this speed range. If any abnormal sounds are heard, stop the engine and inspect for cause.

Alarm sounds during operation.

• If the alarm sounds during operation, lower the engine speed immediately, check the warning lamps and stop the engine for repairs.

6LY3 LDC Operation Manual

Page 72

Is there water, oil or fuel leakage? Are there any loose bolts or connections?

• Check the engine room daily for any leaks or loose connections.

Is there sufficient fuel in the fuel tank?

• Refill fuel in advance to avoid running out of fuel. If the tank runs out of fuel, bleed the fuel system. See Bleeding the Fuel System on page 26.

When operating the engine at low speed for long periods of time, race the engine once every 2 hours. Racing the engine with the clutch in NEUTRAL, accelerate from the low speed position to the high speed position and repeat this process about five times. This is done to clean out carbon from the cylinders and the fuel injection valves. NOTICE: Neglecting

to race the engine will result in poor exhaust color and reduce engine performance.

Periodically operate the engine near maximum speed 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 the following information:

• Model name 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 such as high

altitude or extreme ambient temperatures, etc.

• Engine maintenance history and previous problems

• Other factors that contribute to the problem

TROUBLESHOOTING

6LY3 LDC Operation Manual

Page 73

TROUBLESHOOTING CHART

Symptom Probable Cause Measure Reference

Alarm indicators and alarm sound come on in the display during operation.

Shift to low speed operation immediately, and check which indicator has come on in the display. Stop the engine for inspection. If no abnormality is identified and there is no problem with operation, return to the port at lowest speed and request repairs.

• Lube oil low pressure alarm indicator comes on.

• Engine lube oil level is low. • Check lube oil level. Add or replace.

Checking Engine Oil on page 28.

• Lube oil filter clogged. • Replace lube oil filter. Replace lube oil.

Replace Engine Oil and Engine Oil Filter on page 52.

• Marine gear lube oil pressure alarm indicator comes on.

• Marine gear lube oil is low. • Check the oil level and supply.

—

• Coolant high temperature alarm indicator comes on.

• Coolant / fresh water in coolant tank is low.

• Check coolant level and replenish.

Check Diesel Fuel, Engine Oil and Engine Coolant Levels on page

50.

• Insufficient seawater causing temperature to rise.

• Check seawater system. —

• Contamination inside cooling 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 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 rocker switch returned to ON from START after engine starts:

• Buzzer keeps on sounding.

• Sensor switches faulty (if indicator comes on).

• Short-circuit (if indicator does not come on).

• See your authorized Yanmar Marine dealer or distributor.

—

• One of the alarm indicators comes on.

• Sensor switches engine faulty. • See your authorized Yanmar Marine dealer or distributor.

—

• Battery low charge indicator comes on during operation.

• V-belt is loose or broken. • Replace V-belt; adjust tension.

Adjust Alternator V-Belt Tension on page 56.

• Battery defective. • Check battery fluid level, specific gravity. Replace.

Check the Battery on page 55.

• Alternator power generation fail-

ure.

• See your authorized Yanmar Marine dealer or distributor.

—

• DC-DC Converter failure. • See your authorized Yanmar Marine dealer or distributor.

—

White Exhaust Smoke at Start

• Poor fuel quality. • Replace with fresh fuel. —

Black Smoke on Acceleration

• Propeller too large.

• Hull bottom dirty.

• Replace with correct size.

• Clean hull bottom.

—

TROUBLESHOOTING

6LY3 LDC Operation Manual

Page 74

This Page Intentionally Left Blank

TROUBLESHOOTING

6LY3 LDC Operation Manual

Page 75

LONG-TERM STORAGE

BEFORE YOU PLACE THE ENGINE IN LONG-TERM STORAGE

Before performing any storage procedures within this section, review the Safety section on page 4.

In cold temperatures or before long-term storage, be sure to drain the seawater from the cooling system.

CAUTION! DO NOT drain 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 be necessary to use a stiff wire to remove any debris to allow drainage.

2. Loosen the six bolts attaching the side cover of the seawater pump, remove the cover and drain the water from inside. Retighten the bolts when finished.

6LY3 LDC Operation Manual

Page 76

3. Close the drain cocks.

Note: Do not drain the coolant (freshwater cooling system). If the coolant is drained, the cooling system components could corrode.

Before placing the engine in storage, perform the following:

1. Clean the outside of the engine, wiping off any dust or oil.

2. Drain the fuel or fill the tank completely to help prevent condensation inside the tank.

3. Refill the heat exchanger with engine coolant.

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 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 in the fuel tank was removed, and prime the fuel system.

3. Confirm that there is engine coolant in the engine.

4. Operate the engine at idle speed for 1 minute.

5. Check fluid levels and check engine for leaks.

LONG-TERM STORAGE

6LY3 LDC Operation Manual

Page 77

SPECIFICATIONS

PRINCIPAL ENGINE SPECIFICATIONS

Engine Model 6LY3-STC 6LY3-UTC

Use Light Duty Commercial

Type Vertical water cooled 4 cycle diesel engine

Aspiration Turbocharger with Intercooler

Combustion System Direct injection

Number of Cylinders 6

Bore x Stroke 105.9 × 110 mm (4.17 × 4.33 in)

Displacement 5.813 L (355 cu. in.)

Continuous Power

Output at Crankshaft Engine / Speed

3198 min-1 (rpm)

295 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° to 81°C (160° to 190°F)

Lubrication System Complete enclosed forced lubrication

Normal Oil Pressure Range 4.0 to 5.0 bar (58 to 73 psi)

6LY3 LDC Operation Manual

Page 78

Engine Model 6LY3-STC 6LY3-UTC

Coolant Capacity (fresh)

Engine: 28 L (30 qt) Coolant recovery tank:

1.5 L (1.6 qt)

Engine Lubricating Oil Capacity

Rake Angle rake angle 0 deg

Total (Note 4) 18.8 L (19.9 qt)

Effective (Note 5) 8.0 L (8.5 qt)

Starting System

Type Electric

Starting Motor DC 12V - 3kWDC 24V - 3.5kW (option)

AC Generator

12V - 80A24V-35A with DC-DC Converter

(option)

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 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

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

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

SPECIFICATIONS

6LY3 LDC Operation Manual

Page 79

Wiring Diagrams

Wiring Diagram - 12 V

SPECIFICATIONS

6LY3 LDC Operation Manual

Page 80

Wiring Diagram - 24 V (Optional)

ＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥ

ＥＥＥ

ＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥ.5Ｅ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

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

Water T.

Fuel T.

Oil T.

Boost P.

Oil P.

J:JA4

ＥＥＥＥＥＥＥＥＥＥＥ

10A

ＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

G11C/BBr(0.5)

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

E51/YL(0.5)Throtle position

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

Timer solenoid/Retard

ＥＥＥＥＥＥＥＥＥＥ

B21A/GR(0.5)Emergency Stop

E12/W(0.5)Air heater-A

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

E01A/W(1.25)Starter ON

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

B12A/G(0.5)2nd staition key

B11A/L(0.5)1st staition key

B20/LW(0.5)ECU main relay

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

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

ＥＥＥＥＥＥＥＥＥＥＥ

ENG EARTH

ＥＥＥＥＥＥＥＥＥＥＥ

ENG EARTH

E60/W(1.25)Actuator

Ｅ

E38/%L(0.5)/Cam pulse +

E37/%B(0.5)/pulse -

Ｅ

E36/%W(0.5)/pulse +

ＥＥＥ

20A

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

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

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥ

ＥＥＥ

ECU

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

J:MT1

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ.ＥＥ

ＥＥＥＥＥＥＥＥＥ.ＥＥ

ＥＥＥＥＥＥＥＥ.ＥＥ

ＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥ

Timer advance

Timer retard

ＥＥＥＥＥＥＥＥ

B07A

ＥＥＥＥＥＥＥＥ

B01E/R(8)

B01D/R(5)

ＥＥＥ

Ｅ

ＥＥＥＥＥＥＥＥＥＥ

ENG EARTH

ＥＥＥＥ

ＥＥＥＥＥＥＥＥ

ＥＥＥ

ＥＥＥＥＥＥＥＥ.ＥＥ

ＥＥＥＥＥＥ

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

12Ｅ

Ｅ

ＥＥＥＥＥＥＥＥ

GND

ＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥ

Service Tool

ＥＥＥ

Ｅ

DEUTSCH DT06-12SA-CE05

DEUTSCH DT04-12PA-CE07

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

RW(1.25)

ＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥ

ＥＥ

981

311410512267

ＥＥＥＥＥＥＥＥＥＥ

Timer solenoid/Advance

Emergency

Stop SW

Normally close

Ignition SW

J:MW1

ＥＥＥＥＥ

J:ME4

ＥＥＥＥＥ

J:W-1

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

J:MT2

J:MT3

J:JA1

B21A/GR(1.25)

ＥＥＥＥ

G10C

J:MW6

Alternator

L B

ＥＥＥ→ＥＥＥ

24V GND

ＥＥＥＥＥＥＥＥＥ

Ｅ

24V GND

G01/B(8)

ＥＥＥＥＥＥ

ENG EARTH

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥ

ＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

Ignition switch circuit

○○○

○

○ ○

off

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

Starter

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

OEM Responsibilty

ＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥ

ＥＥＥＥＥＥＥ

ＥＥＥ

TELEFLEX

components

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥ

ＥＥＥＥＥＥＥＥＥＥＥＥＥＥＥ

0006654

SPECIFICATIONS

6LY3 LDC Operation Manual

Page 81

Wiring Harness - Pin Location for 24 V (Optional)

0006653

SPECIFICATIONS

6LY3 LDC Operation Manual

Page 82

This Page Intentionally Left Blank

SPECIFICATIONS

6LY3 LDC Operation Manual

Page 83

EPA WARRANTY USA

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).

For Commercial Use:

0006536

(119578-07701)

Figure 1

6LY3 LDC Operation Manual

Page 84

THIS EMISSION WARRANTY APPLIES TO THE ENGINES CERTIFIED TO UNITED STATES EPA 40 CFR 94 AND SOLD BY YANMAR THAT ARE INSTALLED IN VESSELS FLAGGED OR REGISTERED IN THE UNITED STATES.

Your Warranty Rights and Obligations:

Yanmar warrants to the first user and each subsequent purchaser the emission control system on your engine for periods of time listed below provided the engine has been installed according to Yanmar installation requirements and there has been no abuse, neglect, or improper maintenance to your Yanmar Marine engine.

Yanmar warrants that the engine is designed, built and tested using genuine parts and equipped so as to conform to all applicable emission requirements of the U.S. Environmental Protection Agency and is free from defects in material and workmanship which would cause this engine to fail to conform to the applicable emission regulations over its limited emission control system warranty period.

Where a warrantable emissions 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 the emission control components and systems performed by any repair establishment or individual and may elect to use parts other than Yanmar parts for such maintenance, replacement or repair. However, the cost of such service or parts and subsequent failures form such service or parts will not be covered under this emission control system warranty:

Warranty Period:

The warranty starts on either the date of delivery to the first end-user, or the date the unit is first leased, rented or loaned.

For Commercial Use: The warranty period is 5 years or 5000 hours of use, whichever comes first. In the absence of a device to measure hours of use, the engine warranty period is 5 years.

EPA WARRANTY USA ONLY

6LY3 LDC Operation Manual

Page 85

Warranty Coverage:

Repair or replacement of any warranted parts will be performed at an authorized Yanmar Marine dealer or distributor. This limited emission control system warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser. Such components may include the following:

1. Fuel Injection System

2. Turbocharger System

3. Aftercooler

4. Electronic Engine Control Units and its associated Sensor and Actuators

Exclusions:

Failures other than those arising from defects in material and / or workmanship are not covered by this limited emissions warranty. This warranty does not extend to the following: malfunction caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance, improper storage or use of nonrecommended fuels and lubricating oils, accident-caused damage, and replacement of expendable and / or consumable 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 your failure to ensure the performance of all scheduled maintenance.

Your engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with applicable emission requirements. You are responsible for initiating the warranty process. You must present your marine engine to an authorized Yanmar Marine dealer or distributor as soon as a problem exists.

Customer Assistance:

If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar Marine dealer or distributor, you should contact Yanmar Marine USA Corporation for assistance.

Yanmar Marine USA Corporation

101 International Parkway Adairsville, GA 30103 USA

Telephone: 770–877–9894 Fax: 770–877–7567

EPA WARRANTY USA ONLY

6LY3 LDC Operation Manual

Page 86

Maintenance Log

Date Operating

Hours

Maintenance Performed Dealer Name Stamp or Signa-

ture

EPA WARRANTY USA ONLY

6LY3 LDC Operation Manual

Page 87

Date Operating

Hours

Maintenance Performed Dealer Name Stamp or Signa-

ture

EPA WARRANTY USA ONLY

6LY3 LDC Operation Manual

Page 88

This Page Intentionally Left Blank

EPA WARRANTY USA ONLY

6LY3 LDC Operation Manual