Yanmar Marine Diesel Engine 6LY3-ETP/-STP/-UTP Service Repair Manual

6LY3 series 6LY3 Service Manual SERVICE MANUAL P/N: 0BLY3-U00100 MARINE ENGINES Downloaded from www.Manualslib.com manuals search engine

ii 6LY3 Service Manual © 2007 Yanmar Marine International This Service Manual has been developed for the exclusive use of service and repair professionals such as Yanmar authorized distributors and Yanmar authorized dealers. It is written with these professionals in mind and may not contain the necessary detail or safety statements that may be required for a non-professional to perform the service or repair properly and / or safely. Please contact an authorized Yanmar repair or service professional before working on your Yanmar product. Disclaimers: All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations, and / or specifications to explain and / or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time. Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries. All Rights Reserved: No part of this publication may be reproduced or used in any form, by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without the written permission of Yanmar Marine International. © 2007 Yanmar Marine International. 1107 Downloaded from www.Manualslib.com manuals search engine

6LY3 Service Manual iii © 2007 Yanmar Marine International TABLE OF CONTENTS Page Introduction ......................................................................................... 1-1 Safety.................................................................................................... 2-1 General Service Information .............................................................. 3-1 Periodic Maintenance ......................................................................... 4-1 Engine .................................................................................................. 5-1 Fuel System ......................................................................................... 6-1 Coolant System ................................................................................... 7-1 Lubrication .......................................................................................... 8-1 Turbocharger ....................................................................................... 9-1 Starter ................................................................................................. 10-1 Alternator ........................................................................................... 11-1 Electrical and ECU ............................................................................ 12-1 Troubleshooting ................................................................................ 13-1 Service Standards ............................................................................. 14-1 Downloaded from www.Manualslib.com manuals search engine

6LY3 Service Manual 1-1 © 2007 Yanmar Marine International 6LY3 Service Manual Section 1 INTRODUCTION This manual gives specific instructions for the proper repair of Yanmar 6LY3 series marine engines. Please follow the procedures carefully to ensure quality service. Yanmar recommends reading this Service Manual completely before starting with repairs. Along with standard tools, Yanmar recommends the use of special tools necessary to perform repairs correctly. Yanmar products are continuously undergoing improvement. This Service Manual has been checked carefully in order to avoid errors. However, Yanmar is not liable for any misrepresentations, errors of description or omissions. Contact your authorized Yanmar marine dealer or distributor for any questions you have regarding this Service Manual. Downloaded from www.Manualslib.com manuals search engine

INTRODUCTION Revision History 1-2 6LY3 Service Manual © 2007 Yanmar Marine International REVISION HISTORY This manual is a living document. Periodic manual revisions are published to document product improvements and changes. This practice ensures the manual has the most current information. As manual revisions become necessary, individual pages are prepared and sent to those who need the information. If a page or number of pages should be replaced, the replacement information is sent along with a revised Revision Control Table. Discard the older, obsolete information. At times, the revision involves inserting additional pages in one or more sections. Replace the Revision Control Table and insert the new pages. This method of revision control represents the most cost-effective solution to providing current, updated information as needed. Revision Control Table Revision Date Revision Number New Page Numbers Involved Remarks Initiating Department Aug. 2007 Rev. 0 ALL Initial Release YMI Downloaded from www.Manualslib.com manuals search engine

6LY3 Service Manual 2-1 © 2007 Yanmar Marine International 6LY3 Service Manual Section 2 SAFETY SAFETY STATEMENTS Yanmar is concerned for your safety and the condition of your marine engine. Safety statements are one of the primary ways to call your attention to the potential hazards associated with Yanmar marine engines. Follow the precautions listed throughout the manual before operation, during operation and during periodic maintenance procedures for your safety, the safety of others and to protect the performance of your marine engine. Keep the decals from becoming dirty or torn and replace them if they are lost or damaged. Also, if a part needs to be replaced that has a decal attached to it, make sure to order the new part and decal at the same time. Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. Indicates a situation which can cause damage to the engine, personal property and / or the environment or cause the equipment to operate improperly. A 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. Downloaded from www.Manualslib.com manuals search engine

SAFETY Safety Precautions 2-2 6LY3 Service Manual © 2007 Yanmar Marine International SAFETY PRECAUTIONS There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operating, performing repairs or maintenance. The safety messages that follow have DANGER level hazards. These safety messages describe a hazardous situation which, if not avoided, will result in death or serious injury. NEVER permit anyone to install or operate the engine without proper training. • Read and understand this Service Manual before operating or servicing the engine to ensure that safe operating practices and maintenance procedures are followed. • Safety signs and decals are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar marine dealer or distributor for additional training. Crush Hazard NEVER stand under a hoisted engine. If the hoist mechanism fails, the engine will fall on you. ALWAYS secure the engine solidly to prevent the engine from falling during maintenance. The safety messages that follow have WARNING level hazards. These safety messages describe a hazardous situation which, if not avoided, could result in death or serious injury. Explosion Hazard While the engine is running or the battery is charging, hydrogen gas is being produced and can be easily ignited. Keep the area around the battery well-ventilated and keep sparks, open flame and any other form of ignition out of the area. ALWAYS turn off the battery switch (if equipped) or disconnect the negative (-) battery cable before servicing the equipment. Fire and Explosion Hazard Diesel fuel is flammable and explosive under certain conditions. NEVER use a shop rag to catch the fuel. Wipe up all spills immediately. NEVER refuel with the engine running. Store any containers containing fuel in a well-ventilated area, away from any combustibles or sources of ignition. Downloaded from www.Manualslib.com manuals search engine

SAFETY Safety Precautions 12/05 6LY3 Service Manual 2-3 © 2007 Yanmar Marine International Fire Hazard Have appropriate safety equipment available. Have all fire extinguishers checked periodically for proper operation and / or readiness. ALWAYS read and follow safety-related precautions found on containers of hazardous substances like parts cleaners, primers, sealants and sealant removers. Undersized wiring systems can cause an electrical fire. Entanglement Hazard NEVER leave the key in the key switch when servicing the engine. Attach a “Do Not Operate” tag near the key switch while performing maintenance on the equipment. ALWAYS stop the engine before beginning service. If the engine must be serviced while it is operating, remove all jewelry, tie back long hair and keep hands, other body parts and clothing away from moving / rotating parts. Piercing Hazard Avoid skin contact with high-pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line. High-pressure fuel can penetrate your skin and result in serious injury. If you are exposed to high-pressure fuel spray, obtain prompt medical treatment. NEVER check for a fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar marine dealer or distributor repair the damage. Flying Object Hazard ALWAYS wear eye protection when servicing the engine or when using compressed air or high-pressure water. Dust, flying debris, compressed air, pressurized water or steam may injure your eyes. Coolant Hazard Wear eye protection and rubber gloves when handling Long Life Coolant (LLC). If contact with the eyes or skin should occur, flush eyes and wash immediately with clean water. Downloaded from www.Manualslib.com manuals search engine

SAFETY Safety Precautions 2-4 6LY3 Service Manual © 2007 Yanmar Marine International Sever Hazard NEVER wear jewelry, unbuttoned cuffs, ties or loose-fitting clothing and ALWAYS tie long hair back when working near moving / rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts. The propeller may rotate during towing or if the engine is running at idle speed. NEVER service the engine while being towed or when the engine is running. If the vessel has more than one engine, NEVER service an engine if either of the engines is running. In multi-engine configurations the propeller for an engine that is shut down may rotate if any of the other engines are running. Electrical Hazard Make welding repairs safely. • ALWAYS turn off the battery switch (if equipped) or disconnect the negative (-) battery cable and the leads to the alternator when welding on the equipment. • Remove the multi-pin connector to the engine control unit. Connect the weld clamp to the component to be welded and as close as possible to the welding point. • NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a mounting bracket. • When welding is complete, reconnect the leads to the alternator and engine control unit prior to reconnecting the batteries. ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions and damaged or corroded connectors. NEVER turn off the battery switch (if equipped) or short the battery cables during operation. Damage to the electrical system will result. Exhaust Hazard All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning. • NEVER block windows, vents or other means of ventilation if the engine is operating in an enclosed area. • ALWAYS ensure that all connections are tightened to specifications after repair is made to the exhaust system. Burn Hazard Some of the engine surfaces become very hot during operation and shortly after shutdown. • Keep hands and other body parts away from hot engine surfaces. • Handle hot components with heat-resistant gloves. Downloaded from www.Manualslib.com manuals search engine

Yanmar Marine Diesel Engine 6LY3-ETP/-STP/-UTP Service Repair Manual

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