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

MARINE

ENGINE

6LY3

series

OPERATION MANUAL

6LY3–STC 6LY3–UTC

P/N: 0ALY3–G00200

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

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

iii

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

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

6LY3 LDC Operation Manual

This Page Intentionally Left Blank

TABLE OF CONTENTS

6LY3 LDC Operation Manual

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.

6LY3 LDC Operation Manual

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

6LY3 LDC Operation Manual

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.

6LY3 LDC Operation Manual

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

6LY3 LDC Operation Manual

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

6LY3 LDC Operation Manual

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

6LY3 LDC Operation Manual

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

6LY3 LDC Operation Manual

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

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

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

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

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

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

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

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

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

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

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

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)).

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6LY3 LDC Operation Manual

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.

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6LY3 LDC Operation Manual

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

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6LY3 LDC Operation Manual

+ 61 hidden pages

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

Specifications and Main Features

Frequently Asked Questions

User Manual