Yanmar 6LY3 series Bedienungsanleitung

6LY3

series

OPERATION MANUAL

6LY3 Operation Manual

P/N: 0A1957-G0000

MARINE

ENGINES

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ii 6LY3 Operation Manual

Disclaimers:

We reserve the right to change specifications and to improve our products without notice

or obligation. 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.

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6LY3 Operation Manual iii

INTRODUCTION

6LY3 Operation Manual

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

leisure 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.

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INTRODUCTION

iv 6LY3 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:___________________________________________________________

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6LY3 Operation Manual 1

TABLE OF

CONTENTS

6LY3 Operation Manual

Page

Introduction..................................................................... iii

Record of Ownership........................................... iv

Table of Contents ........................................................... 1

Safety............................................................................... 1

Safety Precautions ..................................................... 2

Before You Operate............................................. 2

During Operation and Maintenance..................... 3

Product Overview ......................................................... 21

Yanmar 6LY3 Features and Applications................. 21

Component Identification................................... 22

Operation Side ............................................ 22

Non-Operation Side .................................... 23

Location of Labels ............................................. 24

Nameplate................................................................ 25

Function of Major Components ......................... 26

Electronic Control System (ECS)....................... 27

Display ........................................................ 28

Before You Operate...................................................... 35

Diesel Fuel ............................................................... 40

Diesel Fuel Specifications ................................. 40

Filling the Fuel Tank .......................................... 41

Bleeding the Fuel System.................................. 43

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TABLE OF CONTENTS

26LY3 Operation Manual

Engine Oil ................................................................. 44

Engine Oil Specifications ................................... 44

Engine Oil Viscosity ........................................... 45

Checking Engine Oil........................................... 45

Selection of Marine Gear Oil .............................. 45

Engine Coolant ......................................................... 46

Engine Coolant Specifications ........................... 47

Coolant (Fresh Water Cooling System) ............. 47

Cranking ................................................................... 50

Daily Checks............................................................. 51

Visual Checks .................................................... 51

Check Diesel Fuel, Engine Oil,

and Engine Coolant Levels.......................... 52

Checking and Refilling Marine Gear Oil ............. 52

Checking the Control Head ................................ 52

Checking the Alarm Indicators ........................... 52

Preparing Fuel, Oil, and Coolant in Reserve...... 52

Engine Operation .......................................................... 53

Starting the Engine ................................................... 64

Before Starting the Engine ................................. 64

To Start the Engine ............................................ 64

Shifting ............................................................... 66

Cautions During Operation ....................................... 67

Shutting Down the Engine ........................................ 70

Normal Shutdown............................................... 70

Emergency Shutdown ........................................ 70

Periodic Maintenance ................................................... 73

Safety Precautions ................................................... 73

Before You Operate ........................................... 73

During Operation and Maintenance ................... 74

Precautions............................................................... 90

The Importance of Periodic Maintenance .......... 90

Performing Periodic Maintenance ...................... 91

The Importance of Daily Checks ........................ 91

Keep a Log of Engine Hours and Daily Checks. 91

Yanmar Replacement Parts ............................... 91

Tools Required................................................... 91

Ask Your Authorized Yanmar Marine Dealer

for Help............................................................... 91

Required EPA Maintenance - USA Only............ 92

EPA Installation Requirements - USA Only ....... 92

Tightening Fasteners ......................................... 92

Standard Torque Chart ...................................... 92

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TABLE OF CONTENTS

6LY3 Operation Manual 3

Periodic Maintenance Schedule ........................ 93

Inspection and Maintenance of EPA

Emission-Related Parts............................... 95

Periodic Maintenance Procedures..................... 96

After Initial 50 Hours of Operation............... 96

Replace Engine Oil and Engine

Oil Filter ................................................ 96

Check the Electronic Control

System Operation ................................. 98

Adjust the Propeller Shaft Alignment .... 98

Every 50 Hours of Operation....................... 99

Drain Fuel Filter and Fuel Filter / Water

Separator .............................................. 99

Check the Battery ............................... 101

Adjust Alternator V-Belt Tension......... 103

Every 250 Hours of Operation................... 104

Check the Fuel Injector Spray Pattern 104

Adjust Intake / Exhaust Valve

Clearance (1st Time) .......................... 104

Drain the Fuel Tank ............................ 105

Replace the Fuel Filter Element ......... 106

Replace the Engine Oil (Crankcase) .. 106

Replace the Engine Oil Filter

Element............................................... 106

Check the Seawater Pump Impeller ... 106

Replace the Anode ............................. 107

Clean the Air Intake Silencer .............. 107

Clean the Exhaust / Water Mixing

Elbow .................................................. 108

Clean the Turbocharger Blower.......... 108

Flush the Aftercooler........................... 108

Check the Wiring Connectors ............. 108

Tighten All Major Nuts and Bolts ........ 108

Check / Replace the Flexible Engine

Mounts ................................................ 108

Replace Engine Coolant ..................... 109

Every 500 Hours of Operation................... 109

Replace the Seawater Pump Impeller 109

Adjust the Propeller Shaft Alignment .. 109

Check Alternator Belt Tension ............ 109

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TABLE OF CONTENTS

46LY3 Operation Manual

Every 1000 Hours of Operation ................. 110

Check the Fuel Injector Spray

Pattern................................................. 110

Clean and Check the Seawater

Passages ............................................ 110

Replace Alternator Belt ....................... 110

Adjust Intake / Exhaust Valve

Clearance............................................ 110

Replace Flexible Engine Mounts......... 110

Every 2000 Hours of Operation ................. 111

Overhaul and Check Fuel Feed

Pump................................................... 111

Clean Engine Oil Cooler...................... 111

Clean Seawater and Engine

Coolant System................................... 111

Replace Rubber Fuel Hoses ............... 111

EPA Requirements........................................... 112

EPA Certification Plates ................................... 112

Conditions to Ensure Compliance with EPA

Emission Standards ......................................... 112

Inspection and Maintenance ............................ 113

Troubleshooting.......................................................... 115

Troubleshooting Chart...................................... 116

Troubleshooting Information ............................ 117

Long-Term Storage..................................................... 119

Before You Place the Engine in Long-Term

Storage ................................................................... 119

Returning the Engine to Service............................. 120

Specifications.............................................................. 121

Principal Engine Specifications ........................ 121

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6LY3 Operation Manual 1

SAFETY

6LY3 Operation Manual

Yanmar considers safety of great

importance and recommends that anyone

who comes into close contact with its

products, such as those who 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.

ADANGER

Danger (the word “DANGER” is

in white letters with a red

rectangle behind it) – indicates

an imminently hazardous

situation which, if not avoided,

will result in death or serious

injury. Danger is limited to the

most extreme situations.

0000001en

AWARNING

Warning (the word “WARNING”

is in black letters with an orange

rectangle behind it) – indicates a

potentially hazardous situation

which, if not avoided, could

result in death or serious injury.

0000001en

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SAFETY

26LY3 Operation Manual

SAFETY PRECAUTIONS

Before You Operate

ACAUTION

Caution (the word “CAUTION” is

in black letters with a yellow

rectangle behind it) – indicates a

potentially hazardous situation

which, if not avoided, may result

in minor or moderate injury.

0000001en

CAUTION

Caution without the safety alert

symbol indicates a potentially

hazardous situation that can

cause damage to the engine,

personal property and / or the

environment or cause the engine

to operate improperly.

0000001enMarine

CAUTION

NEVER permit anyone to install

or operate the engine without

proper training.

• Read and understand this

Operation Manual before you

operate or service the engine

to ensure that you follow safe

operating practices and

maintenance procedures.

• Safety signs and labels are

additional reminders for safe

operating and maintenance

techniques.

• See your authorized Yanmar

marine dealer or distributor for

additional training.

0000002enMarine

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