Series: Operation Manual

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6LY3
series
OPERATION MANUAL
6LY3 Operation Manual
P/N: 0A1957-G0000
MARINE
ENGINES
Back
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.
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.
© 2005 Yanmar Marine International.
ii 6LY3 Operation Manual

Back
INTRODUCTION
Welcome to the world of Yanmar Marine! • Make sure this manual is transferred to
Yanmar Marine offers engines, drive subsequent owners. This manual should
systems and accessories for all types of be considered a permanent part of the
boats, from runabouts to sailboats, and engine and remain with it.
from cruisers to mega yachts. In marine
• Constant efforts are made to improve the
leisure boating, the worldwide reputation of
quality and performance of Yanmar
Yanmar Marine is second to none. We
products, so some details included in
design our engines to respect nature. This
this Operation Manual may differ slightly
means quieter engines, with minimal
from your engine. If you have any
vibrations, cleaner than ever. All of our
questions about these differences,
engines designed after 1996 meet most of
please contact your authorized Yanmar
the present and future emission
marine dealer or distributor.
regulations, like BSO II, SAV, EPA II, IMO
and RCD. • The specifications and components
(instrument panel, fuel tank, etc.)
To help you enjoy your Yanmar 6LY3
described in this manual may differ from
engine for many years to come, please
ones installed on your vessel. Please
follow these recommendations:
refer to the manual provided by the
• Read and understand this Operation manufacturer of these components.
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.
6LY3 Operation Manual iii

INTRODUCTION Back
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:___________________________________________________________
iv 6LY3 Operation Manual

Back
TABLE OF
CONTENTS
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
6LY3 Operation Manual 1

TABLE OF CONTENTS Back
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
2 6LY3 Operation Manual

Back TABLE OF CONTENTS
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

TABLE OF CONTENTS Back
Every 1000 Hours of Operation ................. 110
Check the Fuel Injector Spray
Pattern................................................. 110
Clean and Check the Seawater
Passages ............................................ 110
Replace Alternator Belt ....................... 110
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

Back
SAFETY
Yanmar considers safety of great
importance and recommends that anyone A DANGER
who comes into close contact with its Danger (the word “DANGER” is
products, such as those who install, in white letters with a red
operate, maintain or service Yanmar rectangle behind it) – indicates
products, exercise care, common sense an imminently hazardous
and comply with the safety information in situation which, if not avoided,
this manual and on the machine’s safety will result in death or serious
labels. Keep the labels from becoming injury. Danger is limited to the
dirty or torn and replace them if they are most extreme situations.
lost or damaged. Also, if you need to 0000001en
replace a part that has a label attached to
it, make sure you order the new part and
label at the same time. A WARNING
Warning (the word “WARNING”
This safety alert symbol is in black letters with an orange
A
appears with most safety rectangle behind it) – indicates a
statements. It means potentially hazardous situation
attention, become alert, your
m
which, if not avoided, could
safety is involved! Please result in death or serious injury.
read and abide by the
0000001en
message that follows the
safety alert symbol.

SAFETY Back
SAFETY PRECAUTIONS
A CAUTION
Caution (the word “CAUTION” is Before You Operate
in black letters with a yellow
rectangle behind it) – indicates a CAUTION
potentially hazardous situation
which, if not avoided, may result
in minor or moderate injury.
0000001en
CAUTION
NEVER permit anyone to install
Caution without the safety alert
or operate the engine without
symbol indicates a potentially
proper training.
hazardous situation that can
cause damage to the engine, • Read and understand this
personal property and / or the Operation Manual before you
environment or cause the engine operate or service the engine
to operate improperly. to ensure that you follow safe
0000001enMarine
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

Back SAFETY
During Operation and
Maintenance A DANGER
A DANGER
SCALD HAZARD!
EXPLOSION HAZARD! • NEVER remove the fill cap if
• Keep the area around the the engine is hot. Steam and
battery well-ventilated. While hot engine coolant will spurt
the engine is running or the out and seriously burn you.
battery is charging, hydrogen Allow the engine to cool down
gas is produced which can be before you attempt to remove
easily ignited. the fill cap.
• Keep sparks, open flame and • Securely tighten the fill cap
any other form of ignition away after you check the heat
while the engine is running or exchanger. Steam can spurt
battery is charging. out during engine operation if
• Failure to comply will result in the cap is loose.
death or serious injury. • ALWAYS check the level of
0000003en engine coolant by observing
the reserve tank.
• Failure to comply will result in
death or serious injury.
0000002en6LY3
A DANGER
FIRE AND EXPLOSION

HAZARD!
• Diesel fuel is flammable and
explosive under certain
conditions.
• NEVER use diesel fuel as a
cleaning agent.
0000012en

SAFETY Back
A DANGER A DANGER
FIRE AND EXPLOSION FIRE AND EXPLOSION

HAZARD! HAZARD!
• Diesel fuel is flammable and • Diesel fuel is flammable and
explosive under certain explosive under certain
conditions. conditions.
• NEVER remove the fuel cap • Only fill the fuel tank with
with the engine running. diesel fuel. Filling the fuel tank
• Failure to comply will result in with gasoline may result in a
death or serious injury. fire and will damage the
engine.
0000011en
• NEVER refuel with the engine
running.
A DANGER
• Wipe up all spills immediately.
• Keep sparks, open flames or
any other form of ignition
(match, cigarette, static
FIRE AND EXPLOSION electric source) well away
HAZARD! when refueling.
• Only use the key switch to start • NEVER overfill the fuel tank.
the engine.
• Fill the fuel tank. Store any
• NEVER jump start the engine. containers containing fuel in a
Sparks caused by shorting the well-ventilated area, away from
battery to the starter terminals any combustibles or sources
may cause a fire or explosion. of ignition.
• Failure to comply will result in • Failure to comply will result in
death or serious injury. death or serious injury.
0000004en
0000005en

Back SAFETY
A DANGER A DANGER
FIRE AND EXPLOSION

EXPLOSION HAZARD! HAZARD!
• NEVER check the remaining • Diesel fuel is extremely
battery charge by shorting out flammable and explosive under
the terminals. This will result in certain conditions.
a spark and may cause an
• Before you operate the engine,
explosion or fire. Use a
check for fuel leaks. Replace
hydrometer to check the
rubberized fuel hoses every
remaining battery charge.
two years or every 2000 hours
• If the electrolyte is frozen, of engine operation, whichever
slowly warm the battery before comes first, even if the engine
you recharge it. has been out of service.
• Failure to comply will result in Rubberized fuel lines tend to
death or serious injury. dry out and become brittle
0000007en
after two years or 2000 hours
of engine operation, whichever
comes first.
0000015en

SAFETY Back
A DANGER A DANGER
FIRE AND EXPLOSION CRUSH HAZARD!

HAZARD! • When you need to transport an
• Diesel fuel is extremely engine for repair have a helper
flammable and explosive under assist you attach it to a hoist
certain conditions. and load it on a truck.
• When you prime the fuel • NEVER stand under hoisted
system, operate the fuel engine. If the hoist mechanism
priming lever of the fails, the engine will fall on
mechanical fuel pump several you, causing serious injury or
times until the fuel filter cup is death.
filled with fuel. • Failure to comply will result in
• NEVER open the air vent valve death or serious injury.
while the fuel system is being 0000008en
primed. The fuel filter has an
internal air bleed port.
0000016en

Back SAFETY
A WARNING A WARNING
EXHAUST HAZARD!
SEVER HAZARD! • NEVER operate the engine in
• Keep hands and other body an enclosed area such as a
parts away from garage, tunnel, underground
moving / rotating parts such as room, manhole or ship’s hold
the flywheel or PTO shaft. without proper ventilation.
• Wear tight fitting clothing and • NEVER block windows, vents,
keep your hair short or tie it or other means of ventilation if
back while the engine is the engine is operating in an
running. enclosed area. All internal
• Remove all jewelry before you combustion engines create
operate or service the engine. carbon monoxide gas during
operation. Accumulation of
• NEVER start the engine in
this gas within an enclosure
gear. Sudden movement of the
could cause illness or even
engine and / or vessel could
death.
cause death or serious
personal injury. • Make sure that all connections
are tightened to specifications
• NEVER operate the engine
after repair is made to the
without the guards in place.
exhaust system.
• Before you start the engine
• Failure to comply could result
make sure that all bystanders
in death or serious injury.
are clear of the area.
0000003en
• Keep children and pets away
while the engine is operating.
• Check before starting the
engine that any tools or shop
rags used during maintenance
have been removed from the
area.
0000002enMarine

SAFETY Back
A WARNING A WARNING
ALCOHOL AND DRUG

HAZARD!
EXPOSURE HAZARD!
while you are under the • Wear personal protective
influence of alcohol or drugs. equipment such as gloves,
work shoes, eye and hearing
• NEVER operate the engine protection as required by the
when you are feeling ill. task at hand.
• Failure to comply could result • NEVER wear jewelry,
in death or serious injury. unbuttoned cuffs, ties or loose
0000004en fitting clothing when you are
working near moving / rotating
parts such as the flywheel or
PTO shaft.
• ALWAYS tie back long hair
when you are working near
moving / rotating parts such as
a flywheel or PTO shaft.
while wearing a headset to
listen to music or radio
because it will be difficult to
hear the warning signals.
0000005enMarine

Back SAFETY
A WARNING A WARNING
SUDDEN MOVEMENT
HAZARD!
• Be sure the boat is in open
water away from other boats,
docks, and other obstructions HIGH PRESSURE
before increasing rpm. HAZARD!
• Failure to comply could result • Avoid skin contact with high
in death or serious injury. pressure diesel fuel spray
0000006enMarine caused by a fuel system leak
such as a broken fuel injection
line. High pressure fuel can
A WARNING penetrate your skin and result
in serious injury. If you are
exposed to high pressure fuel
spray, obtain prompt medical
treatment.
BURN HAZARD!
• NEVER check for a fuel leak
• Batteries contain sulfuric acid. with your hands. ALWAYS use
NEVER allow battery fluid to a piece of wood or cardboard.
come in contact with clothing, Have your authorized Yanmar
skin or eyes. Severe burns marine dealer or distributor
could result. ALWAYS wear repair the damage.
safety goggles and protective
clothing when servicing the • Failure to comply could result
battery. If battery fluid contacts in death or serious injury.
0000008enMarine
the eyes and / or skin,
immediately flush the affected
area with a large amount of
clean water and obtain prompt
medical treatment.
0000007en

SAFETY Back
A WARNING A WARNING
ENTANGLEMENT
SHOCK HAZARD! HAZARD!
• Turn off the battery switch (if • Stop the engine before you
equipped) or disconnect the begin to service it.
negative battery cable before
• NEVER leave the key in the key
servicing the electrical system.
switch when you are servicing
• Check the electrical harnesses the engine. Someone may
for cracks, abrasions, and accidentally start the engine
damaged or corroded and not realize you are
connectors. ALWAYS keep the servicing it. This could result
connectors and terminals in a serious injury.
clean.
• If you must service the engine
• Failure to comply could result while it is operating, remove all
in death or serious injury. jewelry, tie back long hair, and
0000009en keep your hands, other body
parts and clothing away from
moving / rotating parts.
0000010en
A WARNING
BURN HAZARD!
• Wait until the engine cools
before you drain the engine
coolant. Hot engine coolant
may splash and burn you.
0000016en

Back SAFETY
A WARNING A WARNING
BURN HAZARD! FIRE HAZARD!

• If you must drain the engine oil • Undersized wiring systems can
while it is still hot, stay clear of cause an electrical fire.
the hot engine oil to avoid
being burned. • Failure to comply could result
• ALWAYS wear eye protection. 0000027en
0000011en
A CAUTION
A WARNING
COOLANT HAZARD!
BURN HAZARD! • Wear eye protection and
• Keep your hands, and other rubber gloves when you
body parts, away from hot handle Long Life or Extended
engine surfaces such as the Life engine coolant. If contact
muffler, exhaust pipe, with the eyes or skin should
turbocharger (if equipped) and occur, flush eyes and wash
engine block during operation immediately with clean water.
and shortly after you shut the • Failure to comply may result in
engine down. These surfaces minor or moderate injury.
are extremely hot while the
0000005en
engine is operating and could
seriously burn you.
0000015en

SAFETY Back
A CAUTION 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.
0000152en
FLYING OBJECT HAZARD!

• ALWAYS wear eye protection CAUTION
when servicing engine and The illustrations and
when using compressed air or descriptions of optional
high-pressure water. Dust, equipment in this manual, such
flying debris, compressed air, as the operator’s console, are for
pressurized water or steam a typical engine installation.
may injure your eyes. Refer to the documentation
• Failure to comply may result in supplied by the optional
minor or moderate injury. equipment manufacturer for
0000003en specific operation and
maintenance instructions.
0000018en
CAUTION
• Only use diesel fuels
recommended by Yanmar for CAUTION
the best engine performance, If any indicator illuminates
to prevent engine damage and during engine operation, stop
to comply with EPA warranty the engine immediately.
requirements. Determine the cause and repair
the problem before you continue
• Only use clean diesel fuel.
to operate the engine.
• NEVER remove primary 0000029en
strainer from the fuel tank filler
port. If removed, dirt and
debris could get into the fuel
system causing it to clog.
0000004enMarine
CAUTION
If any problem is noted during
the visual check, the necessary
corrective action should be
taken before you operate the
engine.
0000021en

Back SAFETY
CAUTION CAUTION
• If the vessel is equipped with a Observe the following
water lift (water lock) muffler, environmental operating
excessive cranking could conditions to maintain engine
cause seawater to enter the performance and avoid
cylinders and damage the premature engine wear:
engine. If the engine does not • NEVER run the engine if the
start after cranking 15 ambient temperature is above
seconds, close the thru-hull +40°C (+104°F) or below -16°C
water intake valve to avoid (+5°F)
filling the muffler with water.
Crank for 15 seconds or until ◆ If the ambient temperature
the engine starts. When the exceeds +40°C (+104°F) the
engine does start, stop the engine may overheat and
engine immediately and press cause the engine oil to break
the switch to the OFF position. down.
◆ If the ambient temperature
• Be sure to re-open the seacock falls below -16°C (+5°F)
and restart the engine. Operate rubber components such as
the engine normally. gaskets and seals will
0000151en harden causing premature
engine wear and damage.
CAUTION ◆ See your authorized Yanmar
marine engine dealer or
NEVER hold the key in the
distributor if the engine will
START position for longer than
be operated in either
15 seconds or the starter motor
temperature extreme.
will overheat.
0000007en
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.
0000065enMarine

SAFETY Back
CAUTION CAUTION
• Only use the engine coolant • NEVER overfill the engine with
specified. Other engine engine oil.
coolants may affect warranty • ALWAYS keep the oil level
coverage, cause an internal between upper and lower lines
buildup of rust and scale on the oil cap / dipstick.
and / or shorten engine life.
0000015en
• Prevent dirt and debris from
contaminating engine coolant.
Carefully clean the heat
CAUTION
exchanger cap and the For maximum engine life,
surrounding area before you Yanmar recommends that when
remove the cap. shutting the engine down, you
allow the engine to idle, without
• NEVER mix different types of
load, for 5 minutes. This will
engine coolants. This may
allow the engine components
adversely affect the properties
that operate at high
of the engine coolant.
temperatures, such as the
0000006enTrans
turbocharger (if equipped) and
exhaust system, to cool slightly
CAUTION before the engine itself is shut
• Only use the engine oil down.
specified. Other engine oils 0000008en
may affect warranty coverage,

cause internal engine CAUTION
components to seize, or
NEVER use an engine starting
shorten engine life.
aid such as ether. Engine
• Prevent dirt and debris from damage will result.
contaminating engine oil. 0000009en
Carefully clean the oil
cap / dipstick and the
surrounding area before you
remove the cap.
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.
0000005en

Back SAFETY
CAUTION CAUTION
Make sure the engine is installed New Engine Break In:
on a level surface. If a Yanmar • On the initial engine start-up,
Marine Engine is installed at an check for proper engine oil
angle that exceeds the pressure, diesel fuel leaks,
specifications stated in the engine oil leaks, coolant leaks,
Yanmar Marine Engine Operation and for proper operation of the
Manual, engine oil may enter the indicators and / or gauges.
combustion chamber causing
excessive engine speed, white • During the first 50 hours of
exhaust smoke and serious operation operate your new
engine damage. This applies to engine under a substantial
engines that run continuously or load at all times. For best
those that run for short periods break-in results operate the
of time. engine at various speeds.
0000010enMarine • Operating the engine in
NEUTRAL must be avoided.
During the first 50 hours, avoid
CAUTION operation below 2000 rpm.
Be careful not to get any oil on
• During the break-in period,
the V-belt. Oil on the belt causes
carefully observe the engine
slipping and stretching. Replace
oil pressure and engine
the belt if it is damaged.
temperature.
0000153en
check the engine oil and
CAUTION coolant levels frequently.
If seawater is left inside of the 0000011enMarine
engine, it may freeze and
damage parts of the cooling
system when the ambient
CAUTION
temperature is below 0°C (32°F). NEVER allow engine oil or diesel
0000154en
fuel oil to contact the flexible
rubber mount. Oil makes rubber
deteriorate.
0000155en

SAFETY Back
CAUTION CAUTION
If the alarm window with audible
alarm fails to display and go out
about three seconds later when
the rocker switch is pushed to
the ON position, see your
• ALWAYS be environmentally authorized Yanmar marine dealer
responsible. or distributor for service before
• Follow the guidelines of the operating the engine.
EPA or other governmental 0000028enMarine
agencies for the proper

disposal of hazardous CAUTION
materials such as engine oil,
diesel fuel and engine coolant. NEVER use the Emergency Stop
Consult the local authorities or switch for a normal engine
reclamation facility. shutdown. Use this switch only
when stopping the engine
• NEVER dispose of hazardous suddenly in an emergency.
materials irresponsibly by
0000156en
dumping them into a sewer, on
the ground or into ground
water or waterways. CAUTION
• Failure to follow these Establish a periodic
procedures may seriously maintenance plan according to
harm the environment. the engine application and make
0000013en
sure you perform the required
periodic maintenance at
intervals indicated. Failure to
CAUTION follow these guidelines will
Protect the air cleaner, impair the engine’s safety and
turbocharger (if equipped) and performance characteristics,
electric components from shorten the engine’s life and may
damage when you use steam or affect the warranty coverage on
high-pressure water to clean the your engine.
engine. 0000024en
0000014en

Back SAFETY
CAUTION CAUTION
It is important to perform daily Clean or replace the air cleaner
checks as listed in the Operation element if the air intake
Manual. restriction exceeds the value
Periodic maintenance prevents listed in the Operation and
unexpected downtime, reduces Service Manuals.
the number of accidents due to 0000046enMarine
poor engine performance and

helps extend the life of the CAUTION
engine.
NEVER turn off the battery
0000060enMarine
switch (if equipped) or short the
battery cables during operation.
CAUTION Damage to the electric system
If the fuel filter / water separator will result.
is positioned higher than the fuel 0000061en
level in the fuel tank, water may

not drip out when the fuel CAUTION
filter / water separator drain cock
NEVER move the adjustment
is opened. If this happens, turn
nuts without using a hoist to
the air vent screw on the top of
take the pressure off the engine
the fuel filter / water separator
mount. Failure to comply may
2-3 turns counterclockwise.
cause damage to the stud and
Be sure to tighten the air vent nut threads.
screw after the water has drained 0000084en
out.
0000025en
CAUTION
Excessive vibration may cause
CAUTION damage to the engine, marine
• When the engine is operated in gear, hull and onboard
dusty conditions, clean the air equipment. In addition, it causes
cleaner element more noticeable passenger and crew
frequently. discomfort. Carefully select
• NEVER operate the engine with engine mounts and propellers
the air cleaner or element(s) when you design Yanmar marine
removed. This may allow engine applications.
foreign material to enter the 0000085en
engine and damage it.

0000026en

SAFETY Back
CAUTION CAUTION
Sea trials can only be performed If you have an installation with
safely when the vessel is two or three engines, and only
adequately manned. Do not one engine is operating, it is
attempt to single-hand a vessel important to limit the amount of
while collecting and recording throttle applied to the running
performance data. engine. If you observe black
0000086en smoke or movement of the
throttle does not increase engine
RPM, you are overloading the
CAUTION engine that is running.
When you install instrument Immediately throttle back to
panels: approximately 2/3 throttle or to a
• Avoid wet locations setting where the engine
performs normally. Failure to do
• Avoid locations subject to
so may cause the running engine
vibration
to overheat or cause excess
• Set meters at correct angle carbon buildup which may
Failure to follow these shorten the engine's life.
instructions may cause 0000150en
inaccurate or unreliable
instrumentation. CAUTION
0000087en
If you have an installation with
two or three engines, and only
one engine is operating, please
note that if the propeller shaft
thru-hull (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.
0000157en

Back SAFETY
CAUTION
one engine is operating, the
water pickup (thru-hull) of the
non-running 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.
0000158en

SAFETY Back
This Page Intentionally Left Blank

Back
PRODUCT
OVERVIEW
YANMAR 6LY3 FEATURES The engine must be installed correctly with

the seawater or cooling water piping,
AND APPLICATIONS exhaust gas piping and electrical wiring.
The engine is equipped with a marine Any auxiliary equipment attached to the
gear. The marine gear output shaft engine should be easy to use and
connects with the propeller shaft. In order accessible for service. To handle the drive
to obtain full performance from your equipment, propulsion systems (including
engine, it is imperative that you check the the propeller) and other onboard
size and structure of the hull and use a equipment be sure to observe the
propeller of the appropriate size. As new instructions and cautions given in the
boats are used, owners add additional operation manuals supplied by the
equipment and completely fill the fuel and shipyard and equipment manufacturers.
water tanks adding to the overall The laws of some countries may require
displacement (weight) of the vessel. Extra hull and engine inspections, depending on
canvas enclosures, bottom paint, and the use, size and cruising area of the boat.
bottom fouling can add additional hull The installation, fitting and surveying of
resistance. It is recommended that a new this engine all require specialized
vessel be propped so the engine can knowledge and engineering skills. See
operate at 100-200 rpm above maximum Yanmar's local subsidiary in your region or
rpm to allow for some added weight and your authorized Yanmar marine dealer or
hull resistance. Failure to do so can lead to distributor.
reduced vessel performance, lead to
increased smoke levels and cause This engine is designed for pleasure boat
permanent damage to your engine. applications. The engine is designed to be
operated at: Maximum throttle for less than
5% of its total operation time (30 minutes
out of every 10 hours). The engine should
be operated at cruising speed for less than
90% of its total operation time (9 hours out
of every 10 hours).

PRODUCT OVERVIEW Back
COMPONENT IDENTIFICATION
Operation Side
1
3
10
4
9
0002020
5
8 6
7
1. Oil Fill Cap 6. Lube Oil Filter

2. Coolant Fill Cap 7. Inter-Cooler
3. Electronic Control Unit Cover Plate 8. Flywheel
4. Fuel Injection Pump 9. Air Intake Silencer
5. Lube Oil Cooler 10. Turbocharger
Figure 1

Back PRODUCT OVERVIEW
Non-Operation Side
1
8
0002021
3
4
6 5
1. Coolant Tank (Exhaust Manifold) 5. Alternator

2. Dipstick 6. V-Belt
3. Fresh Water Cooler 7. Fuel Filter
4. Seawater Pump 8. Fresh Water Pump
Figure 2

LOCATION OF LABELS 128296-07300
Figure 3 shows the location of regulatory

and safety labels on Yanmar 6LY3 series
engines. Please replace if damaged or
lost.
2
1
3
120324-07240
0002079
Warning Labels 128296-07260

No. Description Part Number
1 Hot Surface 128296-07300
2 Lifting Precautions 120324-07240
3 Engine Coolant Fill Cap 128296-07260
4 Rotating Parts 128296-07350
5 Fall Hazard 119578-07890
128296-07350
Figure 3

119578-07890
DO NOT STEP
ON COVERS.
POSSIBILITY
OF A FALL
NAMEPLATE
The nameplate shown (Figure 4) is
attached to the engine. Check the engine
model, output, rpm and serial number on
the nameplate.
MODEL
CONT. RATING Kw rpm
SPEED OF PROP. rpm
SHAFT
MAX. OUT PUT Kw rpm
ENGINE NO.
YANMAR DIESEL ENGINE
YANMAR CO., LTD.

MADE IN JAPAN
0002019
Figure 4

FUNCTION OF MAJOR COMPONENTS

Name of part Function
Removes dirt and water from fuel. Drain the filter periodically. The element (filter)
Fuel Filter should be replaced periodically. See Replace the Fuel Filter Element on
page 106.
Fuel Pumps fuel from tank to the fuel injection pump. Equipped with built-in centrifugal
Feed Pump vane.
Engine Oil Fill Port The fill port used to add engine lubricating oil.
Lubricating Oil Filter
Filters fine metal fragments and carbon from the lubricating oil. Filtered lube oil is
(At Full-flow and Bypass
distributed to the engine's moving parts.
Sides)
There are two cooling systems: fresh water and seawater. The engine's
combustion heat is cooled by the fresh water / coolant in a closed circuit. The fresh
Cooling Water System 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.
The fresh water cooler is a heat exchanger to cool the fresh water by using
Fresh Water Cooler
seawater.
The centrifugal water pump circulates fresh cooling water inside the engine. The
Fresh Water Pump
fresh water pump is driven by V-belt.
The rubber impeller type pump raises seawater for cooling. Never operate it
Seawater Pump
without seawater, as this will damage the impeller.
The fill cap on the coolant tank covers the water supply port. The cap has a
Fresh Water / Coolant Fill
pressure regulating valve. When the cooling water temperature rises, the pressure
Cap
rises inside the fresh water system.
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
Coolant Recovery Tank
opens to send water back from the coolant recovery tank. This minimizes cooling
water consumption. Fresh water / coolant level can easily be checked and refilled
in this tank.
Oil Cooler This heat exchanger cools high temperature lube oil with seawater.
The pressurized intake air feeding device: the exhaust gas turbine is rotated by
Turbocharger the exhaust gas, and the power is used to rotate the blower. This pressurizes the
intake air for sending to the cylinder.
This heat exchanger cools the pressurized intake air from the turbocharger with
Inter-Cooler
seawater.
The metal area of the seawater cooling system is prone to electrical corrosion. The
anti-corrosion anode is installed in the oil cooler, aftercooler, etc. to prevent this.
Anti-Corrosion Anode The anti-corrosion 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 are provided on the engine and the marine gear and include the
Nameplates
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.

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
Sub throttle active
Eng ON Emergency
OFF
Sub throttle
Stop
Model:i2 Module
8
9
6
0002022
1. First Station Rocker Switch Panel 6. NMEA Tee and Terminators Kit
2. To Engine 7. NMEA Tee Connector
3. Interface Module without Trolling 8. Digital Display
Interface Module with Trolling (Optional) 9. Control Head (Shift and Throttle)
4. To Engine
5. To Marine Gear
Figure 5

Display DUAL PORT
Alarms
The multi-function information display has HOT ENGINE CHECK ENGINE
OVER REV EMERGENCY
the following function.
OIL PRESSURE LOW VOLTAGE
TURBO BOOST ALTERNATOR
Refer to the Electronic Control System
GEAR OIL SEA WATER FLOW
Manual for 6LY3, available as a separate ENG COM ERROR LOW COOLANT
volume, for details. MAINTENANCE WATER IN FUEL
NETWORK THROTTLE PROBLEM
Display Function 0002024
Runtime Engine Data Tri-Screen Figure 7

(Figure 6) Alarm Log Screen (Figure 8)
SINGLE OIL PRES

Port Eng Alarms
Alarm Log
2 3 0 100
84 PSi 061803 17:04 - COM ERROR Y 025
1 4 P0120/FEB0 THROTTLE SENSOR
WTR TEMP VALUE OUT OF RANGE.
0 2615 CONTACT YANMAR DISTRIBUTOR
X1000 RPM
100 250
11 4 Fah
CLR EXIT
0002023 0002025
Figure 6 Figure 8
This screen displays real time engine data Alarm Indicator Functions
and alarm indications.
Alarm indicators and buzzer come on
Alarm Indicators (Figure 7) when sensors detect an abnormality
Alarm window appears with an audible during engine operation. The alarm
alarm when abnormal engine activity indicators are off during normal operation,
occurs. but come on as follows when an
abnormality arises:
Note: When starting the engine, make
it a rule to check that when the • Cooling water temperature alarm
rocker switch is pushed to the indicator comes on when the fresh
ON position, an alarm window water gets too hot.
with an audible rearm appears • Lube oil pressure alarm indicator
on the display and goes out comes on when the engine lube oil
about three seconds later. If the pressure drops.
system does not function • Electric charge alarm indicator comes
normally, contact your on when there is a charging failure.
authorized Yanmar marine
dealer and ask for diagnostics.

Rocker Switch Panel 3. Sub-Throttle Control (Figure 9, (3))
The rocker switch panel has the following In the unlikely event that the throttle
functions. control fails, the sub-throttle indicator
light will flash and the engine speed is
1st Station Panel (Figure 9) controlled the sub-throttle. Engine
speed rises when the sub-throttle knob
1 is turned clockwise.
2
Start • When the sub-throttle indicator
Sub throttle active
Eng ON Emergency
Stop
flashes, turn the sub-throttle knob
OFF 3
Sub throttle
counterclockwise to the end and turn
the knob clockwise gradually until the
sub-throttle indicator turns on (steady
0002026
light).
Figure 9 • Each engine is controlled by a
1. To start and stop the engine: dedicated sub-throttle controller.
• To start the engine, push upper half of 2nd Station Panel - Optional (Figure 10)
ENG ON switch (START).
• To stop the engine, push bottom half of 1
ENG ON switch (OFF).
Start 2
Note: The engine will take 2 to 7 Eng ON Emergency
seconds to stop running after OFF
Stop
the bottom of the rocker switch is

pressed.
2. EMERGENCY STOP (Figure 9, (2)) 0002027
Figure 10
IMPORTANT
Use this switch only in an 1. ENGINE ON switch (Figure 10, (1)) is
emergency. Under normal wired to 1st station panel.
circumstances, use the ENG ON 2. Able to start and stop the engine from
switch (Figure 9, (1)) to stop the 2nd station panel.
engine. 3. EMERGENCY STOP switch is wired in
The engine shuts down suddenly when series with 1st station panel
the upper half of the EMERGENCY (Figure 10, (2)).
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.

Control Head Shift and Throttle Control Head Button Functions
Functions • N (or NEUTRAL) Button – If the
Use the two-lever control head associated control head lever is in the
(Figure 11, (4)) in the helm station for “Neutral Idle” position, pushing this
ahead (Figure 11, (1)), astern button engages / disengages Neutral
(Figure 11, (3)), neutral (Figure 11, (2)) Throttle control, allowing throttle but no
and speed control in a twin installation. forward or reverse thrust. If the
associated control head lever is in a
1 2 “Gear Idle” position, pushing this button
engages / disengages Split Range
Throttle (SRT) (if installed).
3
• SELECT (or SEL) Button – If the station
is inactive, pushing this button activates
the station (used in conjunction with two
0002028
or more control stations).
4
• SYNC Button – Pushing this button
Figure 11 engages / disengages the Cruise
Use the single-lever control head Synchronization option (if installed)
(Figure 12, (4)) in the helm station for when the port and starboard control
ahead (Figure 12, (1)), astern head levers are set to nearly the same
(Figure 12, (3)), neutral (Figure 12, (2)) positions.
and speed control in a single installation.
1
2
0002029
4
Figure 12

Control Head Operation
Selecting Active Station:
F F F F F F
N N N N N N
R R R R R R
N N N N N N
SELECT SYNC SELECT SYNC SELECT SYNC
1 2 3
0002030
Figure 13
(a) (Figure 13, (1)) shows a typical
inactive station.
(b) Press the SELECT button
(Figure 13, (2)). The button lights
Figure 14
(grayed in (Figure 13)) and the
station select light flashes (star Engage:
around light in (Figure 13, ).
(a) Return the handle(s) to neutral. The
(c) Move the handle(s) to forward or neutral light(s) glow steady
reverse throttle to match the handle (Figure 14, (1)).
location of the active station
(Figure 13, (3)). The corresponding (b) Press the NEUTRAL button(s)
handle button lights glow steady (Figure 14, (2)). The neutral light(s)
(grayed in (Figure 13, (3))) and the flash (star around light(s) in
station select light glows steady (Figure 14, (2))).
(grayed in (Figure 13, (3))). (c) Move the handle(s) to forward or
Engaging / Disengaging Shift Disconnect reverse throttle (Figure 14, (3))
Mode: resulting in engine rpm control
without engaging marine gear.
Disengage:
(a) Return the handle(s) to neutral
(Figure 14, (4)).
(b) Press the NEUTRAL button(s)
(Figure 14, (5)). The neutral light(s)
glow steady (Figure 14, (5)).
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 (c) If the system is shifted into neutral
mode gives you greater throttle sensitivity. while in the Split Range Throttle
In Split Range Throttle (SRT), moving an engine mode, the N (Neutral) lamp
engine’s control lever all the way to the will come on (steady) to indicate that
“Full Forward” position will only produce the system is in neutral. When the
the maximum percentage of wide open lever is moved back into gear, the N
throttle selected in the “Features Selection” (Neutral) lamp will resume flashing
of the ECU program options. Typical to indicate that the system is still in
Throttle Limit percentages for SRT are 5% Split Range Throttle.
to 50%, with 25% being the default value. Disengage:
Return the engine lever to a Gear Idle
position (Forward Idle or Reverse
Idle) (Figure 15, (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.
Figure 15
Engage:
(a) Move the engine’s lever to an in-
gear idle position (Forward Idle or
Reverse Idle) (Figure 15, (1)) and
press the N (NEUTRAL) button
(Figure 15, (2)) next to this lever on
the control head. The N (Neutral)
lamp (Figure 15, (2)) will flash to
indicate that the Split Range Throttle
is engaged.
(b) While in the Split Range Throttle, the
system will shift normally but the
throttle will be limited in both gears.

Engaging / Disengaging Cruise Disengage:
Synchronization
Press the SYNC button on the control
head.
Figure 16
Engage:
(a) Disengage any other engine mode
being used.
(b) Match all engine shift and throttle
settings by moving the active port
and starboard control head levers to
within 10% of each other
(Figure 16, (1)) and press the SYNC
button (Figure 16, (2)) on the control
head. The sync lamp flashes if the
handles are not within 10% of each
other (Figure 16, (3)). The sync
lamp will stop flashing and remain
continuously lit (Figure 16, (4))
when the levers are moved to within
this 10% 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 10%
of each other and are above 20%
throttle.


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

proper training.
• Read and understand this
Operation Manual before you
operate or service the engine
to ensure that you follow safe
techniques.
0000002enMarine

BEFORE YOU OPERATE Back
A DANGER A DANGER
FIRE AND EXPLOSION

HAZARD!
SCALD HAZARD! • Diesel fuel is flammable and
• NEVER remove the fill cap if
conditions.
the engine is hot. Steam and
hot engine coolant will spurt • Only fill the fuel tank with
out and seriously burn you. diesel fuel. Filling the fuel tank
Allow the engine to cool down with gasoline may result in a
before you attempt to remove fire and will damage the
the fill cap. engine.
• Securely tighten the fill cap • NEVER refuel with the engine
after you check the heat running.
exchanger. Steam can spurt • Wipe up all spills immediately.
out during engine operation if
the cap is loose.
• ALWAYS check the level of (match, cigarette, static
engine coolant by observing electric source) well away
the reserve tank. when refueling.
• Failure to comply will result in • NEVER overfill the fuel tank.
0000002en6LY3
containers containing fuel in a
well-ventilated area, away from
any combustibles or sources
of ignition.
0000005en

Back BEFORE YOU OPERATE
A DANGER A DANGER
FIRE AND EXPLOSION

HAZARD! FIRE AND EXPLOSION
• Diesel fuel is extremely
HAZARD!
flammable and explosive • Diesel fuel is extremely
under certain conditions. flammable and explosive
under certain conditions.
• Be sure to place the diesel fuel
container on the ground when • When you prime the fuel
transferring the diesel fuel system, operate the fuel
from the pump to the priming lever of the
container. Hold the hose mechanical fuel pump several
nozzle firmly against the side times until the fuel filter cup is
of the container while filling it. filled with fuel.
This prevents static electricity • NEVER open the air vent valve
buildup which could cause while the fuel system is being
sparks and ignite fuel vapors. primed. The fuel filter has an
• NEVER place diesel fuel or internal air bleed port.
other flammable material such • Failure to comply will result in
as oil, hay or dried grass close death or serious injury.
to the engine during engine 0000016en
operation or shortly after shut
down.
0000014en

A WARNING A WARNING
HIGH PRESSURE BURN HAZARD!

HAZARD! • If you must drain the engine oil
while it is still hot, stay clear of
• Avoid skin contact with high
pressure diesel fuel spray
being burned.
caused by a fuel system leak
such as a broken fuel injection • ALWAYS wear eye protection.
line. High pressure fuel can • Failure to comply could result
penetrate your skin and result in death or serious injury.
in serious injury. If you are 0000011en
treatment. A WARNING
with your hands. ALWAYS use
a piece of wood or cardboard.
Have your authorized Yanmar
marine dealer or distributor BURN HAZARD!
repair the damage. • Keep your hands, and other
• Failure to comply could result body parts, away from hot
in death or serious injury. engine surfaces such as the
0000008enMarine
muffler, exhaust pipe,
engine block during operation
and shortly after you shut the
engine down. These surfaces
seriously burn you.
0000015en

A WARNING CAUTION
recommended by Yanmar for
the best engine performance,
to prevent engine damage and
BURN HAZARD! to comply with EPA warranty
requirements.
before you drain the engine • Only use clean diesel fuel.
coolant. Hot engine coolant • NEVER remove primary
may splash and burn you. strainer from the fuel tank filler
• Failure to comply could result port. If removed, dirt and
in death or serious injury. debris could get into the fuel
0000016en
0000004enMarine
A CAUTION
CAUTION
• Only use the engine oil
specified. Other engine oils
cause internal engine
COOLANT HAZARD! shorten engine life.
• Wear eye protection and • Prevent dirt and debris from

rubber gloves when you contaminating engine oil.
handle Long Life or Extended Carefully clean the oil
Life engine coolant. If contact cap / dipstick and the
with the eyes or skin should surrounding area before you
occur, flush eyes and wash remove the cap.
immediately with clean water. • NEVER mix different types of
• Failure to comply may result in engine oil. This may adversely
minor or moderate injury. affect the lubricating
0000005en
damage.
0000005en

Additional Technical Fuel
CAUTION Requirements
• Only use the engine coolant
• The fuel cetane number should be equal
specified. Other engine
to 45 or higher.
coolants may affect warranty
coverage, cause an internal • The sulfur content must not exceed 0.5%
buildup of rust and scale by volume. Less than 0.05% is preferred.
• NEVER mix kerosene, used engine oil,
• Prevent dirt and debris from or residual fuels with the diesel fuel.
Carefully clean the heat • Water and sediment in the fuel should
exchanger cap and the not exceed 0.05% by volume.
surrounding area before you • Keep the fuel tank and fuel-handling
remove the cap. equipment clean at all times.
• NEVER mix different types of • Poor quality fuel can reduce engine
engine coolants. This may performance and / or cause engine
adversely affect the properties damage.
0000006enTrans
• Fuel additives are not recommended.
Some fuel additives may cause poor
engine performance. See your
DIESEL FUEL distributor for more information.
Diesel Fuel Specifications • Ash content not to exceed 0.01% by
Diesel fuel should comply with the volume.
following specifications. The table lists • Carbon residue content not to exceed
several worldwide specifications for diesel 0.35% by volume. Less than 0.1% is
fuels. preferred.
DIESEL FUEL • Total aromatics content should not

LOCATION exceed 35% by volume. Less than 30%
SPECIFICATION
No. 2-D, No. 1-D, USA
is preferred.
ASTM D975-94 • PAH (polycyclic aromatic hydrocarbons)
EN590:96 European Union content should be below 10% by volume.
ISO 8217 DMX International
BS 2869-A1 or A2 United Kingdom
JIS K2204 Grade No.2 Japan

Diesel Fuel Lines Filling the Fuel Tank
Install the lines between the fuel tank and
the fuel injection pump. A DANGER
Be sure to install a drain cock
(Figure 1, (6)) at the bottom of the fuel
tank to remove water and contaminants.
Install a fuel filter / water separator FIRE AND EXPLOSION
(Figure 1, (3)) and a fuel filter between the HAZARD!
fuel tank and the fuel injection pump. • Diesel fuel is flammable and
1 4
conditions.
2 3
• Only fill the fuel tank with
diesel fuel. Filling the fuel tank
5
with gasoline may result in a
10 fire and will damage the
engine.
9
7 running.
8
6 • Wipe up all spills immediately.
0002050
Figure 1
electric source) well away
Item Description
when refueling.
1 Fuel Filter
• NEVER overfill the fuel tank.
2 Fuel Priming Pump
3 Fuel Filter / Water Separator containers containing fuel in a
4 Fuel Return Line well-ventilated area, away from
5 Fuel Tank
of ignition.
6 Fuel Tank Drain Cock
7 Approximately 50 mm (1.96 in) death or serious injury.
8 Fuel Shutoff Valve 0000005en
9 Less Than 500 mm (19.68 in)

10 To Fuel Injection Pump

A DANGER A DANGER

HAZARD! HAZARD!
• Diesel fuel is extremely • Diesel fuel is extremely
flammable and explosive flammable and explosive
under certain conditions. under certain conditions.
• Be sure to place the diesel fuel • Before you operate the engine,
container on the ground when check for fuel leaks. Replace
transferring the diesel fuel rubberized fuel hoses every
from the pump to the two years or every 2000 hours
container. Hold the hose of engine operation, whichever
nozzle firmly against the side comes first, even if the engine
of the container while filling it. has been out of service.
This prevents static electricity Rubberized fuel lines tend to
buildup which could cause dry out and become brittle
sparks and ignite fuel vapors. after two years or 2000 hours
• NEVER place diesel fuel or of engine operation, whichever
other flammable material such comes first.
as oil, hay or dried grass close • Failure to comply will result in
to the engine during engine death or serious injury.
operation or shortly after shut 0000015en
down.
• Failure to comply will result in CAUTION
0000014en
to comply with EPA warranty
requirements.
• Only use clean diesel fuel.
• NEVER remove primary
strainer from the fuel tank filler
0000004enMarine

Filling the Fuel Tank (Continued) The engine has an automatic air bleed
system. Bleeding the fuel system is not
1. Clean the area around the fuel cap.
required for normal engine operation.
2. Remove the fuel cap from the fuel tank.
The fuel system needs to be bled under
3. Stop fueling when gauge shows fuel
certain conditions:
tank is full. NEVER overfill the fuel tank.
4. Replace the fuel cap and hand-tighten. • Starting the engine for the first time
Over-tightening the fuel cap will • After running out of fuel and fuel has
damage it. been added to the fuel tank
Bleeding the Fuel System • After fuel system maintenance such as
changing the fuel filter and draining the
A DANGER 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.
FIRE AND EXPLOSION When fuel with no air bubbles flows
HAZARD! freely, tighten the air bleed screw.
• Diesel fuel is extremely 2. Loosen the air bleed screw of the fuel
flammable and explosive filter 2 - 3 turns.
under certain conditions. 3. Move the knob on top of feed pump
• When you prime the fuel several times to feed fuel. Continue to
system, operate the fuel move feed pump knob until fuel with no
priming lever of the air bubbles flows freely.
mechanical fuel pump several 4. Tighten the air bleed screw.
times until the fuel filter cup is
filled with fuel. IMPORTANT
• NEVER open the air vent valve NEVER use the starter motor to
while the fuel system is being crank the engine to bleed the fuel
primed. The fuel filter has an system. This may cause the
internal air bleed port. starter motor to overheat and
damage the coils, pinion and / or
• Failure to comply will result in ring gear.
0000016en

ENGINE OIL • JASO (Japanese Automobile Standards

Organization)
CAUTION Notes:
• Only use the engine oil 1. Be sure the engine oil, engine oil
specified. Other engine oils storage containers, and engine oil
may affect warranty coverage, filling equipment are free of
cause internal engine sediments and water.
components to seize, or 2. Change the engine oil after the first
shorten engine life. 50 hours of operation and then at
• Prevent dirt and debris from every 250 hours thereafter.
contaminating engine oil. 3. Select the oil viscosity based on the
Carefully clean the oil ambient temperature where the
cap / dipstick and the engine is being operated. See the
surrounding area before you SAE Service Grade Viscosity Chart
remove the cap. (Figure 2).
• NEVER mix different types of 4. Yanmar does not recommend the
engine oil. This may adversely use of engine oil “additives.”
SAE 10W
• NEVER overfill. Overfilling may SAE 20W
result in white exhaust smoke, SAE 10W-30
engine overspeed or internal SAE 15W-40
damage. SAE 20
SAE 30
0000005en
SAE 40
Engine Oil Specifications

-4˚F 14˚F 32˚F 50˚F 68˚F 86˚F 104˚F
Use an engine oil that meets or exceeds (-20˚C) (-10˚C) (0˚C) (10˚C) (20˚C) (30˚C) (40˚C)
the following guidelines and classifications: 0000005
Figure 2
Service Categories
• API Service Categories CD or higher Additional Technical Engine Oil
• ACEA Service Categories E-3, E-4, and
Requirements:
E-5 The engine oil must be changed when the
Total Base Number (TBN) has been
• JASO Service Category DH-1 reduced to 2.0. TBN (mgKOH/g) test
method; JIS K-2501-5.2-2 (HCI), ASTM
Definitions
D4739 (HCI).
• API Classification (American Petroleum
Institute)
• ACEA Classification (Association des
Constructeurs Européens
d’Automobilies)

Engine Oil Viscosity Adding Engine Oil
SAE 15W40 is the recommended oil 1. Remove the yellow filler port cap
viscosity. (Figure 3, (2)) at the top of the rocker
arm cover (Figure 3, (1)), and fill with
If you operate your engine outside the SAE engine oil.
15W40 ambient temperature limits, select
the appropriate engine oil viscosity based 2. Fill with oil to the upper limit
on the ambient temperature and use the (Figure 3, (4)) on the dipstick
SAE Service Grade Viscosity Chart in (Figure 3, (3)). Insert the dipstick fully
(Figure 2). to check the level.
Checking Engine Oil Engine Lube Oil Capacity

(at rake 0 deg.)
1. Make sure engine is level.
2. Remove dipstick (Figure 3, (3)) and Full: 18.8 L (19.9 quarts)
wipe with clean cloth. Effective: 8 L (8.5 quarts)
3. Fully reinsert dipstick.
• “Full” (Figure 3, (4)) means the oil
4. Remove dipstick. The oil level should amount at the upper limit on a dipstick.
be between upper (Figure 3, (4)) and
• “Effective” means the difference
lower (Figure 3, (5)) lines on the
between oil amount at upper limit and
dipstick.
that at lower limit (Figure 3, (5)).
5. Fully reinsert dipstick.
3. Tighten the filler port (Figure 3, (2))
2 cap securely by hand.
1 Selection of Marine Gear Oil

3
Refer to the instruction book for each
4
5
marine gear.
0002051
Figure 3

ENGINE COOLANT
A CAUTION
A DANGER
COOLANT HAZARD!
• Wear eye protection and
SCALD HAZARD! rubber gloves when you
• NEVER remove the fill cap if handle Long Life or Extended
the engine is hot. Steam and Life engine coolant. If contact
hot engine coolant will spurt with the eyes or skin should
out and seriously burn you. occur, flush eyes and wash
Allow the engine to cool down immediately with clean water.
before you attempt to remove
• Failure to comply may result in
the fill cap.
minor or moderate injury.
• Securely tighten the fill cap 0000005en
after you check the heat
exchanger. Steam can spurt
out during engine operation if CAUTION
the cap is loose. • Only use the engine coolant
• ALWAYS check the level of specified. Other engine
engine coolant by observing coolants may affect warranty
the reserve tank. coverage, cause an internal
buildup of rust and scale
• Failure to comply will result in and / or shorten engine life.
• Prevent dirt and debris from
0000002en6LY3
Carefully clean the heat
exchanger cap and the
surrounding area before you
remove the cap.
0000006enTrans

Engine Coolant Specifications Following the manufacturer’s
recommendations. Use the proper LLC
Use a Long Life Coolant (LLC) that meets
which will not have any adverse effects on
or exceeds the following guidelines and
the materials (cast iron, aluminum, copper,
specifications:
etc.) of the engine’s fresh water cooling
Note: In the U.S., LLC is required for system. See Engine Coolant
the warranty to be valid. Specifications on page 47.
• ASTM D3306, D4985 (US) Replace engine coolant periodically,
according to the maintenance schedule in
• JIS K-2234 (Japan)
this Operation Manual.
• SAE J814C, J1941, J1034 or J2036
Remove scale from the cooling system
(International)
periodically by flushing the system.
Coolant (Fresh Water Cooling
System)
IMPORTANT
Always add LLC to soft
water - especially when operating
in cold weather. Without LLC,
cooling performance will decrease
due to scale and rust in the cooling
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 also.
Do not mix different types or

brands of LLC or a harmful sludge
may form.
Do not use hard water.

Water should be clean and free
from sludge or particles.

Filling Heat Exchanger with Engine This procedure is for filling the heat
Coolant exchanger for the first time or refilling it
after it is flushed. Note that a typical heat
A DANGER exchanger is shown (Figure 4).
1. Close the 4 water drain cocks/plugs (2
for engine coolant and 2 for seawater).
Note: The drain cocks are opened
before shipping from the
production plant.
SCALD HAZARD!
• NEVER remove the fill cap if
the engine is hot. Steam and
hot engine coolant will spurt
out and seriously burn you.
Allow the engine to cool down
the fill cap. 0002052
• Securely tighten the fill cap 2

1
exchanger. Steam can spurt 1. Fresh Water Drain Cock
out during engine operation if 2. Seawater Drain Cock
the cap is loose.
• ALWAYS check the level of Figure 4
engine coolant by observing
the reserve tank.
0000002en6LY3

4. After filling the heat exchanger, replace
2 fill cap and tighten it firmly
(Figure 6, (1)). Failure to do so will
1 cause coolant leakage. To replace the
cap, align the tabs (Figure 6, (2)) on
the bottom of the cap with the notches
on the filler port and turn clockwise 1/3
of a turn.
5. Remove the coolant recovery tank cap
3
0002019 (Figure 7, (2)) and fill with coolant mix
5 4 to the lower limit (Figure 7, (4)).
Replace cap. Never fill to the upper
1. Fresh Water Pump limit (Figure 7, (3)).
2. Coolant Tank Coolant recovery tank capacity: 0.8 L
3. Seawater Drain Cock (1.7 pints)
4. Fresh Water Drain Cock
5. Seawater pump 6. Check the rubber hose (Figure 7, (1))
connecting the coolant recovery tank to
Figure 5
the heat exchanger. Be sure the hose
2. Remove the fill cap (Figure 6, (1)) on is securely connected and there is no
the heat exchanger (Figure 6, (3)) by looseness or damage.
turning the cap counterclockwise 1/3 of If leaks develop in the hose or at the
a turn. connection, an excessive amount of
coolant will be lost.
1
1
2
3
2 4
4
0002054
Figure 7
3
When engine coolant is supplied for the
0002067
first time or when it must be replaced,
Figure 6 conduct a trial operation of the engine for
3. Pour coolant mix slowly into the heat about 5 minutes and check the quantity of
exchanger (Figure 6, (3)) so that air engine oil and coolant.
bubbles do not develop.
Pour until the coolant overflows from the
filler port.

CRANKING 6. Turn the start switch to the ON position.

7. Push and hold the start switch for 15
When the engine has not been used for a
seconds (cranking). Release the start
long period of time, engine oil will not be
switch and the engine stops. Wait for
distributed to all of the operating parts.
15 seconds and repeat again for 15
Using the engine in this condition will lead
seconds. This will distribute oil to the
to seizure.
lubricated parts.
After a long period of no use, distribute 8. Push the SELECT button then push the
engine oil to each part by cranking. N button and the N lamp flashes. Push
Perform in accordance with the following the start switch to start the engine.
procedures before beginning operation. Release the switch when the engine
1. Open seacock. has started. Raise the engine speed
gradually and check for abnormal
2. Open fuel tank cock.
sounds. Also check that sufficient
3. Put remote control lever (Figure 8, (1)) seawater is being discharged from the
in NEUTRAL (Figure 8, (2)). See outlet and that the color of the exhaust
Starting the Engine on page 64. gas is normal. When you raise the
engine speed, more coolant should be
(1) discharged from the outlet.
When engine coolant is supplied for the
first time or when it must be replaced,
conduct a trial operation of the engine for
about 5 minutes and check the quantity of
lubricating oil and coolant.
-N-
SEL
(2)
0003557
Figure 8
4. Press the battery switch.
5. Hold the stop lever of the governor to
the stop position (gear case side) to
stop fuel injection.

DAILY CHECKS CAUTION
Before you head out for the day, make It is important to perform daily
sure the Yanmar engine is in good checks as listed in the Operation
operating condition. Make sure you check Manual.
the following items.
Periodic maintenance prevents
unexpected downtime, reduces
A WARNING the number of accidents due to
helps extend the life of the
engine.
0000060enMarine
HIGH PRESSURE Visual Checks

HAZARD!
1. Check for engine oil leaks.
pressure diesel fuel spray 2. Check for fuel leaks.
caused by a fuel system leak 3. Check for engine coolant leaks.
such as a broken fuel injection 4. Check for damaged or missing parts.
line. High pressure fuel can 5. Check for loose, missing, or damaged
penetrate your skin and result fasteners.
exposed to high pressure fuel 6. Check the electrical harnesses for
spray, obtain prompt medical cracks, abrasions, and damaged or
treatment. corroded connectors.
7. Check hoses for cracks, abrasions, and
damaged, loose or corroded clamps.
a piece of wood or cardboard. 8. Check the fuel filter / water separator
Have your authorized Yanmar for presence of water and
marine dealer or distributor contaminants. If you find any water or
repair the damage. contaminants, drain the fuel filter /
water separator. See Drain Fuel Filter
and Fuel Filter / Water Separator on
page 99. If you have to drain the fuel
0000008enMarine
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 105.

CAUTION
If any problem is noted during
the visual check, the necessary
corrective action should be
engine.
0000021en
Check Diesel Fuel, Engine Oil,

and Engine Coolant LevelsFollow
the procedures in Diesel Fuel on page 40,
Engine Oil on page 44 and Engine
Coolant on page 46 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
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 28.
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) on
board, to be ready for emergencies.

Back
ENGINE
OPERATION
6LY3 OPERATION MANUAL
This section of the Operation Manual
describes the procedures for starting the CAUTION
engine, checking engine performance
during operation, and shutting the engine
down.

proper training.
techniques.
0000002enMarine

ENGINE OPERATION Back
A DANGER A DANGER
EXPLOSION HAZARD!
• Keep the area around the
SCALD HAZARD! battery well-ventilated. While
• NEVER remove the fill cap if the engine is running or the
the engine is hot. Steam and battery is charging, hydrogen
hot engine coolant will spurt gas is produced which can be
out and seriously burn you. easily ignited.
Allow the engine to cool down
• Keep sparks, open flame and
any other form of ignition away
the fill cap.
while the engine is running or
• Securely tighten the fill cap battery is charging.
exchanger. Steam can spurt
out during engine operation if
0000003en
the cap is loose.
• ALWAYS check the level of
engine coolant by observing
the reserve tank.
0000002en6LY3

Back ENGINE OPERATION
A DANGER A DANGER

HAZARD! HAZARD!
• Only fill the fuel tank with • NEVER remove the fuel cap
diesel fuel. Filling the fuel tank with the engine running.
with gasoline may result in a • Failure to comply will result in
fire and will damage the death or serious injury.
engine.
0000011en
running.
when refueling.
of ignition.
0000005en

A DANGER A DANGER

HAZARD! HAZARD!
• Diesel fuel is extremely • Diesel fuel is flammable and
flammable and explosive under explosive under certain
certain conditions. conditions.
• Be sure to place the diesel fuel • Before you operate the engine,
container on the ground when check for fuel leaks. Replace
transferring the diesel fuel rubberized fuel hoses every
from the pump to the two years or every 2000 hours
container. Hold the hose of engine operation, whichever
nozzle firmly against the side comes first, even if the engine
of the container while filling it. has been out of service.
This prevents static electricity Rubberized fuel lines tend to
buildup which could cause dry out and become brittle
sparks and ignite fuel vapors. after two years or 2000 hours
• NEVER place diesel fuel or of engine operation, whichever
other flammable material such comes first.
as oil, hay or dried grass close • Failure to comply will result in
to the engine during engine death or serious injury.
operation or shortly after shut 0000015en
down.
A WARNING
0000014en SUDDEN MOVEMENT
HAZARD!
docks, and other obstructions
before increasing rpm.
0000006enMarine

A WARNING A WARNING
EXHAUST HAZARD!
SEVER HAZARD! • NEVER operate the engine in
• Keep hands and other body an enclosed area such as a
parts away from garage, tunnel, underground
moving / rotating parts such as room, manhole or ship’s hold
the flywheel or PTO shaft. without proper ventilation.
• Wear tight fitting clothing and • NEVER block windows, vents,
keep your hair short or tie it or other means of ventilation if
back while the engine is the engine is operating in an
running. enclosed area. All internal
• Remove all jewelry before you combustion engines create
operate or service the engine. carbon monoxide gas during
• NEVER start the engine in
gear. Sudden movement of the
engine and / or vessel could
death.
personal injury. • Make sure that all connections
without the guards in place.
exhaust system.
0000003en
area.
0000002enMarine

A WARNING A WARNING
ALCOHOL AND DRUG

HAZARD!
EXPOSURE HAZARD!
while you are under the • Wear personal protective
influence of alcohol or drugs. equipment such as gloves,
• NEVER operate the engine protection as required by the
when you are feeling ill. task at hand.
• Failure to comply could result • NEVER wear jewelry,
in death or serious injury. unbuttoned cuffs, ties or loose
0000004en fitting clothing when you are
PTO shaft.
while wearing a headset to
listen to music or radio
because it will be difficult to
hear the warning signals.
0000005enMarine

A WARNING A WARNING
BURN HAZARD!
HIGH PRESSURE
HAZARD! • Keep your hands, and other
body parts, away from hot
engine surfaces such as the
pressure diesel fuel spray
muffler, exhaust pipe,
caused by a fuel system leak
engine block during operation
line. High pressure fuel can
and shortly after you shut the
penetrate your skin and result
engine down. These surfaces
seriously burn you.
treatment.
0000015en
a piece of wood or cardboard.
marine dealer or distributor A WARNING
repair the damage.
0000008enMarine
BURN HAZARD!
A WARNING • Wait until the engine cools
BURN HAZARD! in death or serious injury.
0000016en
• If you must drain the engine oil
being burned.
• ALWAYS wear eye protection.
0000011en

A CAUTION CAUTION
to comply with EPA warranty
requirements.
COOLANT HAZARD! • Only use clean diesel fuel.
• Wear eye protection and • NEVER remove primary
rubber gloves when you strainer from the fuel tank filler
handle Long Life or Extended port. If removed, dirt and
Life engine coolant. If contact debris could get into the fuel
with the eyes or skin should system causing it to clog.
occur, flush eyes and wash 0000004enMarine
immediately with clean water.
CAUTION
0000005en
• Only use the engine oil
CAUTION cause internal engine
Observe the following components to seize, or
environmental operating shorten engine life.
conditions to maintain engine • Prevent dirt and debris from
performance and avoid contaminating engine oil.
premature engine wear: Carefully clean the oil
• Avoid operating in extremely cap / dipstick and the
dusty conditions. surrounding area before you
remove the cap.
• Avoid operating in the
presence of chemical gases or • NEVER mix different types of
fumes. engine oil. This may adversely
0000003enMarine affect the lubricating
damage.
0000005en

CAUTION CAUTION
NEVER hold the key in the The illustrations and
START position for longer than descriptions of optional
15 seconds or the starter motor equipment in this manual, such
will overheat. as the operator’s console, are for
0000007en a typical engine installation.
Refer to the documentation
supplied by the optional
CAUTION equipment manufacturer for
NEVER use an engine starting specific operation and
aid such as ether. Engine maintenance instructions.
damage will result. 0000018en
0000009en
CAUTION
CAUTION If any problem is noted during
• Only use the engine coolant the visual check, the necessary
specified. Other engine corrective action should be
coolants may affect warranty taken before you operate the
coverage, cause an internal engine.
buildup of rust and scale 0000021en
• Prevent dirt and debris from CAUTION
Carefully clean the heat If any indicator illuminates
exchanger cap and the during engine operation, stop
surrounding area before you the engine immediately.
remove the cap. Determine the cause and repair
the problem before you continue
• NEVER mix different types of to operate the engine.
0000029en
0000006enTrans CAUTION
Clean or replace the air cleaner
element if the air intake
restriction exceeds the value
listed in the Operation and
Service Manuals.
0000046enMarine

CAUTION CAUTION
NEVER turn off the battery Observe the following
switch (if equipped) or short the environmental operating
battery cables during operation. conditions to maintain engine
Damage to the electric system performance and avoid
will result. premature engine wear:
0000061en • NEVER run the engine if the
ambient temperature is above
CAUTION +40°C (+104°F) or below -16°C
(+5°F)
NEVER use the Emergency Stop
switch for a normal engine ◆ If the ambient temperature
shutdown. Use this switch only exceeds +40°C (+104°F) the
when stopping the engine engine may overheat and
suddenly in an emergency. cause the engine oil to break
0000156en
down.
◆ If the ambient temperature
falls below -16°C (+5°F)
CAUTION rubber components such as
Be sure to close the seacock. gaskets and seals will
Neglecting to close the seacock harden causing premature
could allow water to leak into the engine wear and damage.
boat and may cause it to sink. ◆ See your authorized Yanmar
marine engine dealer or
0000152en
distributor if the engine will
be operated in either
temperature extreme.
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.
0000065enMarine

CAUTION CAUTION
Excessive vibration may cause If you have an installation with
damage to the engine, marine two or three engines, and only
gear, hull and onboard one engine is operating, it is
equipment. In addition, it causes important to limit the amount of
noticeable passenger and crew throttle applied to the running
discomfort. Carefully select engine. If you observe black
engine mounts and propellers smoke or movement of the
when you design Yanmar marine throttle does not increase engine
engine applications. RPM, you are overloading the
0000085en engine that is running.
Immediately throttle back to
approximately 2/3 throttle or to a
CAUTION setting where the engine
Sea trials can only be performed performs normally. Failure to do
safely when the vessel is so may cause the running engine
adequately manned. Do not to overheat or cause excess
attempt to single-hand a vessel carbon buildup which may
while collecting and recording shorten the engine's life.
performance data. 0000150en
0000086en
CAUTION
CAUTION • If the vessel is equipped with a
When you install instrument water lift (water lock) muffler,
panels: excessive cranking could
• Avoid wet locations cause seawater to enter the
cylinders and damage the
engine. If the engine does not
vibration
start after cranking 15
• Set meters at correct angle seconds, close the thru-hull
Failure to follow these water intake valve to avoid
instructions may cause filling the muffler with water.
inaccurate or unreliable Crank for 15 seconds or until
instrumentation. the engine starts. When the
0000087en
engine does start, stop the
engine immediately and press
the switch to the OFF position.
• Be sure to re-open the seacock
and restart the engine. Operate
the engine normally.
0000151en

STARTING THE ENGINE 1
Before Starting the Engine

1. Open the seacock.
Start
2. Open the fuel tank cock. Sub throttle active
Eng ON Emergency
3. Set the control lever on the control OFF
Stop
head (Figure 1, (2)) in N (NEUTRAL) Sub throttle
(Figure 1, (1)) position.

0002058
1
Figure 3
• The needle appears in the engine
tachometer on the display.
SINGLE OIL PRES
2 0002056 0 100
2 3
84 PSi
1
Figure 1 4
WTR TEMP
0 2615
4. Turn ON the battery switch and the X1000 RPM
100 250
screen (Figure 2) pops up on the 11 4 Fah
display. Then the screen will change to

the engine data display mode.
0002060
TE i5501E Figure 4
Multi-Function Display
To Start the Engine
To start the engine, press START (upper
half) of ENG ON switch (Figure 3, (1)).
Electronic
Controls
If the Engine Fails to Start
V1.0 Copyright Teleflex, Inc.
0002057
CAUTION
Figure 2 NEVER hold the key in the
5. Press the Eng ON (Figure 3, (1)) START position for longer than
switch and the following changes occur: 15 seconds or the starter motor
will overheat.
0000007en

Before pressing the start switch again, 3. Check that exhaust color, engine
confirm that the engine has stopped vibrations, and sound are normal.
completely. If the starter motor is operated 4. When there are no problems, keep the
before the engine has completely stopped, engine at low speed to send engine oil
the starter motor pinion gear will be to all parts of the engine.
damaged.
5. Check that sufficient seawater is
Note: Hold the start switch for a discharged from the seawater outlet
maximum of 15 seconds in the pipe. Operation with inadequate
START position. If the engine seawater discharge will damage the
does not start the first time, impeller of the seawater pump. If
press the rocker switch OFF and seawater discharge is too small, stop
wait for about 15 seconds before the engine immediately. Identify the
trying again. After the engine cause and repair.
has started, do not press the • Is the seacock open?
rocker switch off. (It should
• Is the inlet of the seacock on the hull
remain ON.)
bottom clogged?
• Is the seawater suction hose broken,
CAUTION
or does the hose suck in air due to a
• If the vessel is equipped with a loose joint?
water lift (water lock) muffler,
Note: The engine will seize if it is
excessive cranking could
operated when seawater
cause seawater to enter the
discharge is too small or if load
cylinders and damage the
is applied without any warming
engine. If the engine does not
up operation.
start after cranking 15
seconds, close the thru-hull
water intake valve to avoid
Crank for 15 seconds or until
the engine starts. When the
0000151en
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.

Shifting 2
1
A 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 F
-N-
position then back to the R
3
NEUTRAL position. N
SEL
4
• Observe whether the boat
moves in the direction you 6 5 0002061
expect.
Figure 5
in death or serious injury. Ahead
0000109en
Gradually move the control lever in the F
Neutral (forward) direction (Figure 5, (2)) to the
position of the Forward Detent. The marine
Be sure to set the control lever at N gear will shift into FORWARD. The engine
(NEUTRAL) position (Figure 5, (1)). will remain at idle. Pushing further on the
Note: Clutch operation or the use of control lever will increase the rpm up to a
trolling during high speed will maximum of wide open throttle (WOT).
cause internal parts of the clutch
to break or to wear excessively. Astern
Gradually move the control lever in the R
1. Before using the marine gear, be sure
(reverse) direction to the position of the
to move the control lever (throttle) to a
Reverse Detent. The marine gear will shift
low idle position (the detent position).
into REVERSE. The engine will remain at
Then move the control lever slowly to a
idle. Pulling further on the control lever will
higher speed position after completing
increase the rpm up to a maximum of wide
clutch engagement.
open throttle (WOT).
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 and
fully into the FORWARD, NEUTRAL,
and REVERSE positions.

CAUTIONS DURING CAUTION
OPERATION If you have an installation with
CAUTION one engine is operating, it is
If you have an installation with important to limit the amount of
two or three engines, and only throttle applied to the running
one engine is operating, please engine. If you observe black
note that if the propeller shaft smoke or movement of the
thru-hull (stuffing box) is throttle does not increase engine
lubricated by engine water RPM, you are overloading the
pressure and the engines are engine that is running.
interconnected, care must be Immediately throttle back to
taken that water from the approximately 2/3 throttle or to a
running engine does not enter setting where the engine
the exhaust of the non-running performs normally. Failure to do
engine(s). This water could so may cause the running engine
cause seizure of the non-running to overheat or cause excess
engine(s). See your authorized carbon buildup which may
Yanmar marine dealer or shorten the engine's life.
distributor for a complete 0000150en

0000157en
CAUTION
water pickup (thru-hull) of the
non-running 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.
0000158en

1. Is sufficient seawater being discharged
CAUTION from the exhaust and seawater outlet
New Engine Break In: pipe?
• On the initial engine start-up, If the discharge is small, stop the engine
check for proper engine oil immediately; identify the cause and
pressure, diesel fuel leaks, repair.
engine oil leaks, coolant leaks,
2. Is the exhaust color normal?
and for proper operation of the
indicators and / or gauges. The continuous emission of black
exhaust smoke indicates engine
• During the first 50 hours of overloading. This shortens the engine's
operation operate your new life and should be avoided.
engine under a substantial
load at all times. For best 3. Are there abnormal vibrations or noise?
break-in results operate the
engine at various speeds. CAUTION
• Operating the engine in Excessive vibration may cause
NEUTRAL must be avoided. damage to the engine, marine
During the first 50 hours, avoid gear, hull and onboard
operation below 2000 rpm. equipment. In addition, it causes
• During the break-in period, noticeable passenger and crew
carefully observe the engine discomfort. Carefully select
oil pressure and engine engine mounts and propellers
temperature. when you design Yanmar marine
engine applications.
0000085en
check the engine oil and
coolant levels frequently. Depending on the hull structure, engine
0000011enMarine and hull resonance may suddenly
become great at a certain engine speed
Note: Engine trouble can arise if the range, causing heavy vibrations. Avoid
engine is operated for a long operation in this speed range. If you hear
time under overloaded any abnormal sounds, stop the engine
conditions with the control lever and inspect.
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.
Always be on the lookout for problems
during engine operation.
Pay particular attention to the following:

4. Alarm buzzer sounds during operation. This will generate higher exhaust
temperatures, which will help clean out
CAUTION hard carbon deposits, maintaining
engine performance and prolonging the
If any alarm indicator with
life of the engine.
audible alarm sound appears on
the display during engine
operation, stop the engine CAUTION
immediately. Determine the NEVER turn off the battery
cause and repair the problem switch (if equipped) or short the
before you continue to operate battery cables during operation.
the engine. Damage to the electric system
0000029en6LY3 will result.
0000061en
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.
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.

SHUTTING DOWN THE CAUTION

ENGINE Be sure to close the seacock.
Stop the engine in accordance with the Neglecting to close the seacock
following procedures: could allow water to leak into the
boat and may cause it to sink.
Normal Shutdown
0000152en
1. Return the control lever to NEUTRAL
position. (The N light turns on.) 1
2. Cool the engine down at low speed
(below 1000 rpm) for about 5 minutes.
Start
CAUTION Eng ON
Sub throttle active
Emergency
Stop
OFF
For maximum engine life, Sub throttle
Yanmar recommends that when

shutting the engine down, you 3 0002062
2
allow the engine to idle, without
load, for 5 minutes. This will Figure 6
allow the engine components
that operate at high Emergency Shutdown
temperatures, such as the
Electric Emergency Stop:
exhaust system, to cool slightly
before the engine itself is shut CAUTION
down. NEVER use the Emergency Stop
0000008en switch for a normal engine
shutdown. Use this switch only
3. Push OFF (bottom half) of ENG ON when stopping the engine
switch (Figure 6, (3)). The engine suddenly in an emergency.
shuts down within 2 to 7 seconds 0000156en
normally. The regular engine shutdown
takes time because the controller is Push the upper part of emergency stop
adjusted in the fuel injection timing to switch (Figure 6, (1)) on the right of the
the most suitable position for the next panel and the engine shuts down
start. immediately, without the time lag of regular
4. Turn the battery switch off. engine shutdown. After shutdown push the
bottom part of the emergency stop switch
5. Close the fuel tank cock.
(Figure 6, (2)) to be returned to the former
6. Close the seacock. position.

IMPORTANT
Use this switch only in an A WARNING
emergency. Under normal
circumstances, use the OFF, ON,
START switch (Figure 6, (1)) to
stop the engine.
Note: Restarting the engine after using
the emergency stop may be SEVER HAZARD!
slower or more difficult than • Keep hands and other body
normal starting. parts away from
Mechanical Emergency Stop: the flywheel or PTO shaft.
If for some reason you can’t stop the • Wear tight fitting clothing and
engine by the stop switch on the panel, keep your hair short or tie it
push down the stop lever (Figure 7, (1)) to back while the engine is
the front side (Figure 7, (2)) to shut down running.
the engine in an engine room. When
• Remove all jewelry before you
pushing down the stop lever to the front
operate or service the engine.
side, the trouble indication of the governor
pops up in the display. After the engine • NEVER start the engine in
shutdown return the stop lever to the gear. Sudden movement of the
former position. engine and / or vessel could
When pushing down the ON switch on the personal injury.
panel, check that the trouble indication
does not appear in the display. (normal • NEVER operate the engine
condition) without the guards in place.
1 2
• Check the engine that any
tools or shop rags used during
maintenance have been
removed from the area.
0002063 0000002enMarine
Figure 7


Back
PERIODIC
MAINTENANCE
This section of the Operation Manual SAFETY PRECAUTIONS
describes the procedures for proper care
and maintenance of the engine. Before You Operate
CAUTION

proper training.
techniques.
0000002enMarine

PERIODIC MAINTENANCE Back
During Operation and
Maintenance A DANGER
A DANGER
SCALD HAZARD!
EXPLOSION HAZARD! • NEVER remove the fill cap if
• Keep the area around the the engine is hot. Steam and
battery well-ventilated. While hot engine coolant will spurt
the engine is running or the out and seriously burn you.
battery is charging, hydrogen Allow the engine to cool down
gas is produced which can be before you attempt to remove
easily ignited. the fill cap.
• Keep sparks, open flame and • Securely tighten the fill cap
any other form of ignition away after you check the heat
while the engine is running or exchanger. Steam can spurt
battery is charging. out during engine operation if
• Failure to comply will result in the cap is loose.
death or serious injury. • ALWAYS check the level of
0000003en engine coolant by observing
the reserve tank.
0000002en6LY3

Back PERIODIC MAINTENANCE
A DANGER A DANGER

HAZARD! HAZARD!
• When you remove any fuel • NEVER use diesel fuel as a
system component to perform cleaning agent.
maintenance (such as • Failure to comply will result in
changing the fuel filter) place death or serious injury.
an approved container under
0000012en
the opening to catch the fuel.
• NEVER use a shop rag to catch
the fuel. Vapors from the rag A DANGER
are flammable and explosive.
• Wipe up any spills
immediately.
• Wear eye protection. The fuel FIRE AND EXPLOSION
system is under pressure and HAZARD!
fuel could spray out when you • Diesel fuel is flammable and
remove any fuel system explosive under certain
component. conditions.
• Failure to comply will result in • NEVER remove the fuel cap
death or serious injury. with the engine running.
0000009en • Failure to comply will result in
0000011en

A DANGER A DANGER

HAZARD! HAZARD!
• Only use the key switch to start • Diesel fuel is flammable and
the engine. explosive under certain
• NEVER jump start the engine. conditions.
Sparks caused by shorting the • Only fill the fuel tank with
battery to the starter terminals diesel fuel. Filling the fuel tank
may cause a fire or explosion. with gasoline may result in a
• Failure to comply will result in fire and will damage the
death or serious injury. engine.
0000004en • NEVER refuel with the engine
running.
when refueling.
of ignition.
0000005en

A DANGER A DANGER
FIRE AND EXPLOSION

HAZARD! EXPLOSION HAZARD!
• Diesel fuel is extremely • NEVER check the remaining
flammable and explosive under battery charge by shorting out
certain conditions. the terminals. This will result in
• Before you operate the engine,
check for fuel leaks. Replace
rubberized fuel hoses every
two years or every 2000 hours
of engine operation, whichever • If the electrolyte is frozen,
comes first, even if the engine slowly warm the battery before
has been out of service. you recharge it.
Rubberized fuel lines tend to • Failure to comply will result in
dry out and become brittle death or serious injury.
after two years or 2000 hours 0000007en
of engine operation, whichever
comes first.
A DANGER
0000015en
CRUSH HAZARD!
• When you need to transport an
engine for repair have a helper
assist you attach it to a hoist
and load it on a truck.
• NEVER stand under hoisted
engine. If the hoist mechanism
fails, the engine will fall on
you, causing serious injury or
death.
0000008en

A DANGER A WARNING
FIRE AND EXPLOSION

HAZARD! SEVER HAZARD!
• Diesel fuel is flammable and • Keep hands and other body
explosive under certain parts away from
conditions. moving / rotating parts such as
the flywheel or PTO shaft.
• If the unit has an electric fuel
pump, when you prime the fuel • Wear tight fitting clothing and
system, turn the key switch to keep your hair short or tie it
the ON position for 10 to 15 back while the engine is
seconds to allow the electric running.
fuel pump to prime the system. • Remove all jewelry before you
• If the unit has a mechanical operate or service the engine.
fuel pump, when you prime the • NEVER start the engine in
fuel system, operate the fuel gear. Sudden movement of the
priming lever of the engine and / or vessel could
mechanical fuel pump several cause death or serious
times until the fuel filter cup is personal injury.
filled with fuel. • NEVER operate the engine
• NEVER open the air vent valve without the guards in place.
while the fuel system is being • Before you start the engine
primed. The fuel filter has an make sure that all bystanders
internal air bleed port. are clear of the area.
• Failure to comply will result in • Keep children and pets away
death or serious injury. while the engine is operating.
0000010en
area.
0000002enMarine

A WARNING A WARNING
EXHAUST HAZARD!
ALCOHOL AND DRUG
• NEVER operate the engine in HAZARD!
an enclosed area such as a
garage, tunnel, underground • NEVER operate the engine
room, manhole or ship’s hold while you are under the
without proper ventilation. influence of alcohol or drugs.
• NEVER block windows, vents, • NEVER operate the engine

or other means of ventilation if when you are feeling ill.
the engine is operating in an • Failure to comply could result
enclosed area. All internal in death or serious injury.
combustion engines create 0000004en
carbon monoxide gas during
death.
• Make sure that all connections
exhaust system.
0000003en

A WARNING A WARNING
SUDDEN MOVEMENT
HAZARD!
docks, and other obstructions
before increasing rpm.
EXPOSURE HAZARD! • Failure to comply could result
• Wear personal protective in death or serious injury.
equipment such as gloves, 0000006enMarine
protection as required by the
task at hand. A WARNING
• NEVER wear jewelry,
unbuttoned cuffs, ties or loose
fitting clothing when you are
BURN HAZARD!
PTO shaft. • 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
• NEVER operate the engine clothing when servicing the
while wearing a headset to battery. If battery fluid contacts
listen to music or radio the eyes and / or skin,
because it will be difficult to immediately flush the affected
hear the warning signals. area with a large amount of
• Failure to comply could result clean water and obtain prompt
in death or serious injury. medical treatment.
0000005enMarine • Failure to comply could result
0000007en

A WARNING A WARNING
HIGH PRESSURE SHOCK HAZARD!

HAZARD!
• Turn off the battery switch (if
• Avoid skin contact with high equipped) or disconnect the
pressure diesel fuel spray negative battery cable before
caused by a fuel system leak servicing the electrical system.
line. High pressure fuel can • Check the electrical harnesses
penetrate your skin and result for cracks, abrasions, and
in serious injury. If you are damaged or corroded
exposed to high pressure fuel connectors. ALWAYS keep the
spray, obtain prompt medical connectors and terminals
treatment. clean.
• NEVER check for a fuel leak • Failure to comply could result

with your hands. ALWAYS use in death or serious injury.
a piece of wood or cardboard. 0000009en

marine dealer or distributor
repair the damage.
0000008enMarine

A WARNING A WARNING
ENTANGLEMENT BURN HAZARD!

HAZARD! • If you must drain the engine oil
• Stop the engine before you while it is still hot, stay clear of
begin to service it. the hot engine oil to avoid
• NEVER leave the key in the key being burned.
switch when you are servicing • ALWAYS wear eye protection.
the engine. Someone may
accidentally start the engine
and not realize you are
0000011en
servicing it. This could result
in a serious injury.
• If you must service the engine A WARNING
while it is operating, remove all
jewelry, tie back long hair, and
keep your hands, other body
parts and clothing away from
moving / rotating parts. BURN HAZARD!
• Failure to comply could result • Wait until the engine cools
in death or serious injury. before draining seawater from
0000010en the cooling system. Hot
seawater may splash and burn
you.
A WARNING
0000016enMarine
BURN HAZARD!
0000016en

A WARNING A CAUTION
BURN HAZARD!
• Keep your hands, and other
body parts, away from hot COOLANT HAZARD!
engine surfaces such as the • Wear eye protection and
muffler, exhaust pipe, rubber gloves when you
turbocharger (if equipped) and handle Long Life or Extended
engine block during operation Life engine coolant. If contact
and shortly after you shut the with the eyes or skin should
engine down. These surfaces occur, flush eyes and wash
are extremely hot while the immediately with clean water.
engine is operating and could • Failure to comply may result in
seriously burn you. minor or moderate injury.
• Failure to comply could result 0000005en
A CAUTION
0000015en
A WARNING
FLYING OBJECT HAZARD!

FIRE HAZARD! • ALWAYS wear eye protection
• Undersized wiring systems can when servicing engine and
cause an electrical fire. when using compressed air or
• Failure to comply could result high-pressure water. Dust,
in death or serious injury. flying debris, compressed air,
0000027en pressurized water or steam
may injure your eyes.
0000003en

CAUTION CAUTION
• Only use diesel fuels The illustrations and
recommended by Yanmar for descriptions of optional
the best engine performance, equipment in this manual, such
to prevent engine damage and as the operator’s console, are for
to comply with EPA warranty a typical engine installation.
requirements. Refer to the documentation
• Only use clean diesel fuel. supplied by the optional
equipment manufacturer for
• NEVER remove primary specific operation and
strainer from the fuel tank filler maintenance instructions.
0000018en
0000004enMarine CAUTION
If any indicator illuminates
CAUTION during engine operation, stop
the engine immediately.
If any problem is noted during Determine the cause and repair
the visual check, the necessary the problem before you continue
corrective action should be to operate the engine.
0000029en
engine.
0000021en
CAUTION
CAUTION • If the vessel is equipped with a
water lift (water lock) muffler,
Be sure to close the seacock. excessive cranking could
Neglecting to close the seacock cause seawater to enter the
could allow water to leak into the cylinders and damage the
boat and may cause it to sink. engine. If the engine does not
0000152en start after cranking 15
seconds, close the thru-hull
water intake valve to avoid
Crank for 15 seconds or until
the engine starts. When the
0000151en

CAUTION CAUTION
Observe the following • Only use the engine coolant
environmental operating specified. Other engine
conditions to maintain engine coolants may affect warranty
performance and avoid coverage, cause an internal
premature engine wear: buildup of rust and scale
• NEVER run the engine if the and / or shorten engine life.
ambient temperature is above • Prevent dirt and debris from
+40°C (+104°F) or below -16°C contaminating engine coolant.
(+5°F) Carefully clean the heat
◆ If the ambient temperature exchanger cap and the
exceeds +40°C (+104°F) the surrounding area before you
engine may overheat and remove the cap.
cause the engine oil to break • NEVER mix different types of
down. engine coolants. This may
◆ If the ambient temperature adversely affect the properties
falls below -16°C (+5°F) of the engine coolant.
rubber components such as 0000006enTrans
gaskets and seals will
harden causing premature
engine wear and damage.
CAUTION
◆ See your authorized Yanmar • Only use the engine oil
marine engine dealer or specified. Other engine oils
distributor if the engine will may affect warranty coverage,
be operated in either cause internal engine
temperature extreme. components to seize, or
shorten engine life.
marine dealer or distributor if • Prevent dirt and debris from
you need to operate the engine contaminating engine oil.
at high altitudes. At high Carefully clean the oil
altitudes the engine will lose cap / dipstick and the
power, run rough, and produce surrounding area before you
exhaust gases that exceed the remove the cap.
design specifications. • NEVER mix different types of
0000065enMarine engine oil. This may adversely
damage.
0000005en

CAUTION CAUTION
• NEVER overfill the engine with Make sure the engine is installed
engine oil. on a level surface. If a Yanmar
• ALWAYS keep the oil level Marine Engine is installed at an
between upper and lower lines angle that exceeds the
on the oil cap / dipstick. specifications stated in the
Yanmar Marine Engine Operation
0000015en
Manual, engine oil may enter the
combustion chamber causing
CAUTION excessive engine speed, white
For maximum engine life, exhaust smoke and serious
Yanmar recommends that when engine damage. This applies to
shutting the engine down, you engines that run continuously or
allow the engine to idle, without those that run for short periods
load, for 5 minutes. This will of time.
allow the engine components 0000010enMarine
that operate at high

temperatures, such as the CAUTION
exhaust system, to cool slightly Be careful not to get any oil on
before the engine itself is shut the V-belt. Oil on the belt causes
down. slipping and stretching. Replace
the belt if it is damaged.
0000008en
0000153en
CAUTION
CAUTION
NEVER use an engine starting
aid such as ether. Engine If seawater is left inside of the
damage will result. engine, it may freeze and
0000009en
temperature is below 0°C (32°F).
0000154en
CAUTION
NEVER allow engine oil or diesel
fuel oil to contact the flexible
rubber mount. Oil makes rubber
deteriorate.
0000155en

CAUTION CAUTION
If the alarm window with audible
alarm fails to display and go out
about three seconds later when
the rocker switch is pushed to
the ON position, see your
• ALWAYS be environmentally authorized Yanmar marine dealer
responsible. or distributor for service before
• Follow the guidelines of the operating the engine.
EPA or other governmental 0000028enMarine

disposal of hazardous CAUTION
diesel fuel and engine coolant. NEVER use the Emergency Stop
Consult the local authorities or switch for a normal engine
reclamation facility. shutdown. Use this switch only
when stopping the engine
• NEVER dispose of hazardous suddenly in an emergency.
0000156en
water or waterways. CAUTION
• Failure to follow these Establish a periodic
procedures may seriously maintenance plan according to
harm the environment. the engine application and make
0000013en
sure you perform the required
periodic maintenance at
intervals indicated. Failure to
CAUTION follow these guidelines will
Protect the air cleaner, impair the engine’s safety and
turbocharger (if equipped) and performance characteristics,
electric components from shorten the engine’s life and may
damage when you use steam or affect the warranty coverage on
high-pressure water to clean the your engine.
engine. 0000024en
0000014en

CAUTION CAUTION
It is important to perform daily Clean or replace the air cleaner
checks as listed in the Operation element if the air intake
Manual. restriction exceeds the value
Periodic maintenance prevents listed in the Operation and
unexpected downtime, reduces Service Manuals.
the number of accidents due to 0000046enMarine

helps extend the life of the CAUTION
engine.
NEVER turn off the battery
0000060enMarine
switch (if equipped) or short the
battery cables during operation.
CAUTION Damage to the electric system
If the fuel filter / water separator will result.
is positioned higher than the fuel 0000061en

not drip out when the fuel CAUTION
NEVER move the adjustment
nuts without using a hoist to
take the pressure off the engine
mount. Failure to comply may
2-3 turns counterclockwise.
cause damage to the stud and
Be sure to tighten the air vent nut threads.
screw after the water has drained 0000084en
out.
0000025en
CAUTION
Excessive vibration may cause
CAUTION damage to the engine, marine
• When the engine is operated in gear, hull and onboard
dusty conditions, clean the air equipment. In addition, it causes
cleaner element more noticeable passenger and crew
frequently. discomfort. Carefully select
• NEVER operate the engine with engine mounts and propellers
the air cleaner or element(s) when you design Yanmar marine
removed. This may allow engine applications.
foreign material to enter the 0000085en
engine and damage it.

0000026en

CAUTION CAUTION
Sea trials can only be performed If you have an installation with
safely when the vessel is two or three engines, and only
adequately manned. Do not one engine is operating, it is
attempt to single-hand a vessel important to limit the amount of
while collecting and recording throttle applied to the running
performance data. engine. If you observe black
0000086en smoke or movement of the
throttle does not increase engine
RPM, you are overloading the
CAUTION engine that is running.
When you install instrument Immediately throttle back to
panels: approximately 2/3 throttle or to a
• Avoid wet locations setting where the engine
performs normally. Failure to do
so may cause the running engine
vibration
to overheat or cause excess
• Set meters at correct angle carbon buildup which may
Failure to follow these shorten the engine's life.
instructions may cause 0000150en
inaccurate or unreliable
instrumentation. CAUTION
0000087en
one engine is operating, please
note that if the propeller shaft
thru-hull (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
0000157en

CAUTION
PRECAUTIONS
If you have an installation with The Importance of Periodic
two or three engines, and only Maintenance
water pickup (thru-hull) of the Engine deterioration and wear occurs in
non-running engine(s) should be proportion to length of time the engine has
closed. This will prevent water been in service and the conditions the
from being forced past the engine is subject to during operation.
seawater pump and eventually Periodic maintenance prevents
finding its way into the engine. unexpected downtime, reduces the
The result of water entering the number of accidents due to poor machine
engine could cause seizure or performance and helps extend the life of
other serious problems. the engine.
0000158en

Performing Periodic The Importance of Daily Checks
Maintenance Periodic Maintenance Schedules assume
that the daily checks are performed on a
A WARNING regular basis. Make it a habit of performing
daily checks before the start of each
operating day. See Daily Checks on
page 51.
Keep a Log of Engine Hours and

EXHAUST HAZARD! Daily Checks
• NEVER operate the engine in Keep a log of the number of hours the
an enclosed area such as a engine is run each day and a log of the
garage, tunnel, underground daily checks performed. Also note the
room, manhole or ship’s hold date, type of repair (e.g., replaced
without proper ventilation. alternator), and parts needed for any
• NEVER block windows, vents, service needed between the periodic
or other means of ventilation if maintenance intervals. Periodic
the engine is operating in an maintenance intervals are every 50, 250,
enclosed area. All internal 500, 1000 and 2000 engine hours. Failure
combustion engines create to perform periodic maintenance will
carbon monoxide gas during shorten the life of the engine.
this gas within an enclosure Yanmar Replacement Parts
could cause illness or even Yanmar recommends that you use genuine
death. Yanmar parts when replacement parts are
needed. Genuine replacement parts help
• Make sure that all connections
ensure long engine life.
after repair is made to the Tools Required
exhaust system.
Before you start any periodic maintenance
• Failure to comply could result procedure make sure you have the tools
in death or serious injury. you need to perform all of the required
0000003en tasks.
Perform periodic maintenance procedures Ask Your Authorized Yanmar
in an open, level area free from traffic. If Marine Dealer for Help
possible, perform the procedures indoors
to prevent environmental conditions, such Our professional service technicians have
as rain, wind, or snow, from damaging the the expertise and skills to help you with
engine. any maintenance or service related
procedures you need help with.

Required EPA Maintenance - Tightening Fasteners
USA Only Use the correct amount of torque when
To maintain optimum engine performance you tighten fasteners on the machine.
and compliance with the Environmental Applying excessive torque may damage
Protection Agency (EPA) Regulations, it is the fastener or component and not enough
essential that you follow the Periodic torque may cause a leak or component
Maintenance Schedule on page 93 and failure.
Periodic Maintenance Procedures which
start on page 96. CAUTION
EPA Installation Requirements - The tightening torque in
the Standard Torque
USA Only Chart should be applied
The following are the installation only to the bolts with a “7” head.
requirements for the EPA. Unless these (JIS strength classification: 7T)
requirements are met, the exhaust gas
emissions will not be within the limits • Apply 60% torque to bolts that
specified by the EPA. are not listed.
See Conditions to Ensure Compliance with • Apply 80% torque when
EPA Emission Standards on page 112 for tightened to aluminum alloy.
operating conditions. 0000023en6LY3
STANDARD TORQUE CHART

Thread size × Pitch M6×1.0 M8×1.25 M10×1.5 M12×1.75 M14×1.5 M16×1.5
(mm)
Tightening in·lb 96.0 ± 9.0 - - - - -
Torque ft·lb - 19.0 ± 2.1 37.0 ± 3.6 66.0 ± 7.2 103.0 ± 7.2 170.0 ± 7.2
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

PERIODIC MAINTENANCE Note: Schedule your own periodic
inspection plan according to the
SCHEDULE operational conditions of your
Daily and periodic maintenance are engine and inspect every item.
important to keep the engine its best Neglect of periodic inspections
operating condition. The following is a may lead to engine troubles and
summary of inspection and servicing items shorten the life of the engine.
by inspection interval. Periodic Inspection and servicing at 250
maintenance intervals should vary hours and thereafter require
depending on the uses, loads, fuels and special knowledge and
lubricating oils used, and handling techniques. Consult your
conditions, and are hard to establish Yanmar dealer or distributor.
definitively. The following should be treated Refer to the separate manual of
only as a general standard only. Periodic marine gear for the periodical
Maintenance Procedures on page 96 gives inspection.
a detailed explanation of which parts must
be inspected and the procedure for doing
so for each interval.
c: Check : Replace z: Contact your authorized Yanmar marine dealer or distributor
Periodic Maintenance Interval
Every Every 250 Every 500 Every Every
50 hrs. or hrs. or one hrs. or 2 1000 hrs. 2000 hrs.
System Item Daily one month year years or 4 years or 8 years
whichever whichever whichever whichever whichever
comes comes comes comes comes
first first first first first
Whole Visual inspection of engine
c
exterior
Fuel System Check the fuel level, and refill c
Drain the fuel tank c
Drain the fuel filter and the fuel /
c
water separator
Replace the fuel filter element
Check the fuel injector spray z1 z1
pattern (1st time)
Overhaul and check fuel feed
z
pump
Replace rubber fuel hoses Replace every 2 years or every 2000 hours, whichever comes first.
Lubricating Check the engine oil
Crankcase c
System level
Replace the engine Crankcase
oil (1st time)
Replace the engine oil filter

element (1st time)
Clean engine oil cooler z

c: Check : Replace z: Contact your authorized Yanmar marine dealer or distributor
Periodic Maintenance Interval
Every Every 250 Every 500 Every Every
50 hrs. or hrs. or one hrs. or 2 1000 hrs. 2000 hrs.
System Item Daily one month year years or 4 years or 8 years
whichever whichever whichever whichever whichever
comes comes comes comes comes
first first first first first
Cooling c
System Seawater outlet During
Operation
Check coolant level c
Check the seawater pump impeller c
Every year
Replace the engine coolant When long life coolant is used, replace every two years. See Filling Heat
Exchanger with Engine Coolant on page 48.
Clean & check the seawater
passages z
Clean seawater and engine
cooling system z
Replace anode
Air Intake and Clean the air intake silencer c
Exhaust Clean the exhaust/water mixing
System c
elbow
Clean the turbocharger blower z1
Flush aftercooler z
Electrical Check the alarm indicators c
System Check the electrolyte level in the
c
battery
Adjust / replace the tension of the
c c
alternator belt
Check the wiring connectors c
Engine c
Check for leakage of fuel, engine
Cylinder Head oil and engine coolant After
and Block starting
Tighten all major nuts and bolts z
Adjust intake / exhaust valve z z
clearance (1st time)
Miscellaneous Check the electronic control c
Items system operation c (1st time)
Adjust the propeller shaft z
z
alignment (1st time)
Check / replace flexible engine
c
mounts
1 For EPA requirements, see EPA Requirements on page 112.

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

Inspection and Maintenance of EPA Emission-Related Parts
Parts Interval
Clean fuel injection nozzle 1500 hours
Check fuel injection nozzle adjustment
Check fuel injection pump adjustment
Check turbocharger adjustment 3000 hours
Check electronic engine control unit (ECU) and its associated
sensors and actuators
Note: The inspection and maintenance items shown above to be performed at your
Yanmar dealer or distributor.

PERIODIC MAINTENANCE CAUTION

PROCEDURES • Only use the engine oil
After Initial 50 Hours of may affect warranty coverage,
Operation cause internal engine
Perform the following maintenance after shorten engine life.
the initial 50 hours of operation. • Prevent dirt and debris from
contaminating engine oil.
• Replace Engine Oil and Engine Oil
Carefully clean the oil
Filter
cap / dipstick and the
• Check Electronic Control System surrounding area before you
Operation remove the cap.
• Adjust Propeller Shaft Alignment • NEVER mix different types of
engine oil. This may adversely
Replace Engine Oil and Engine affect the lubricating
Oil Filter properties of the engine oil.
The engine oil on a new engine becomes • NEVER overfill. Overfilling may
contaminated from the initial break-in of result in white exhaust smoke,
internal parts. It is very important that the engine overspeed or internal
initial oil change is performed as damage.
scheduled. 0000005en
It is easiest and most effective to drain the

engine oil after operation while the engine
is still warm.
A WARNING
BURN HAZARD!
• If you must drain the engine oil
being burned.
• ALWAYS wear eye protection.
0000011en

Turn the bypass filter (Figure 1, (3)) an
CAUTION additional one turn clockwise with the
filter wrench.
3
2
1
• ALWAYS be environmentally
responsible.
• Follow the guidelines of the
EPA or other governmental
disposal of hazardous
diesel fuel and engine coolant.
Consult the local authorities or
reclamation facility. 0002073
• NEVER dispose of hazardous Figure 1

dumping them into a sewer, on 5. Fill with new engine oil. See Adding
the ground or into ground Engine Oil on page 45.
water or waterways.
• Failure to follow these CAUTION
procedures may seriously • NEVER overfill the engine with
harm the environment. engine oil.
0000013en • ALWAYS keep the oil level
between upper and lower lines
1. Remove the engine oil dipstick. Attach
on the oil cap / dipstick.
the oil drain pump and pump out the oil.
0000015en
For easier draining, remove the engine
oil fill cap (Figure 1, (2)) (yellow) at the 6. Perform a trial run and check for oil
top of the rocker arm cover. leaks.
2. Remove the engine oil filter 7. Approximately 10 minutes after
(Figure 1, (1)) with a filter wrench (turn stopping the engine, remove the oil
counterclockwise). dipstick and check the oil level. Add oil
if the level is too low.
3. Clean the filter installation face, attach
the new full-flow oil filter, and tighten by
hand until the seal touches.
4. Turn the full-flow oil filter an additional
3/4 of a turn clockwise with the filter
wrench.

When the following inspections are done Check the Electronic Control
and any problem is found, contact your System Operation
Yanmar dealer.
The electric governor on the engine and
1. Checking the control head: the marine gear are connected to the
Check that the control lever moves control head, rocker switch panel and
smoothly. display through electric devices such as
the Engine Interface Module.
Check that the shifting and throttle are
smooth. Adjust the Propeller Shaft
2. Checking the alarm indicators:
Alignment
When pressing the start switch to ON The flexible engine mounts are
position on the rocker switch panel, check compressed a little in the initial engine
that the alarm window appears with the operation which may cause centering
alarm sound for about 3 seconds then misalignment between the engine and the
goes off (normal condition). propeller shaft.
Check that there is no alarm message. Check for any unusual noise and vibration
in the engine / boat hull, while increasing
3. Checking the electrical harnesses: and decreasing the engine speed
Check for cracks, abrasions, and gradually.
damaged, loose or corroded connectors. If there is unusual noise and / or vibration,
this maintenance requires specialized
knowledge and techniques. See your
distributor to adjust the propeller shaft
alignment.

Drain Fuel Filter and
Every 50 Hours of Operation Fuel Filter / Water Separator
Perform the following maintenance every A DANGER

50 hours or one month of operation,
whichever comes first.
• Drain Fuel Filter and Fuel Filter /
Water Separator
FIRE AND EXPLOSION
• Check Battery Electrolyte Level HAZARD!
• Adjust Alternator Belt Tension or • Diesel fuel is flammable and
Replace Alternator Belt explosive under certain
conditions.
• When you remove any fuel
system component to perform
maintenance (such as
changing the fuel filter) place
the opening to catch the fuel.
the fuel. Vapors from the rag
immediately.
• Wear eye protection. The fuel
system is under pressure and
fuel could spray out when you
remove any fuel system
component.
0000009en

Drain the Fuel Filter
CAUTION
If the fuel filter / water separator
is positioned higher than the fuel
not drip out when the fuel
2-3 turns counterclockwise. 1
Be sure to tighten the air vent 0002074A
screw after the water has drained
Figure 2
out.
0000025en 1. Close the fuel tank cock.
2. Loosen the drain plug (Figure 2, (1)).
CAUTION Drain off any water and dirt collected
inside.
Drain the Fuel Filter / Water Separator
• ALWAYS be environmentally
responsible. Element
• Follow the guidelines of the

EPA or other governmental
disposal of hazardous 3
2
1
diesel fuel and engine coolant. 0002075A
Consult the local authorities or Figure 3

reclamation facility.
1. Close the fuel tank drain cock.
• NEVER dispose of hazardous
materials irresponsibly by 2. Loosen the drain plug (Figure 3, (1)) at
dumping them into a sewer, on the bottom of the fuel filter / water
the ground or into ground separator and drain off any water and
water or waterways. dirt.
• Failure to follow these 3. Remove the center bolt (Figure 3, (2))
procedures may seriously to disassemble the fuel filter / water
harm the environment. separator.
0000013en
Clean the element (Figure 3, (3)) inside
with clean fuel.

4. When a fuel filter or fuel filter / water
separator is provided in the hull in A WARNING
addition to those installed on the
engine, also drain and clean them or
replace the element.
5. After reassembly of the fuel filter / water
separator, be sure to bleed air from the BURN HAZARD!
fuel system. See Bleeding the Fuel • Batteries contain sulfuric acid.
System on page 43. NEVER allow battery fluid to
come in contact with clothing,
Check the Battery skin or eyes. Severe burns
could result. ALWAYS wear
A DANGER 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
EXPLOSION HAZARD! clean water and obtain prompt
• NEVER check the remaining medical treatment.
battery charge by shorting out • Failure to comply could result
the terminals. This will result in in death or serious injury.
0000007en
• If the electrolyte is frozen,
slowly warm the battery before
you recharge it.
0000007en

Check the fluid level periodically. If the
CAUTION level is lower than the minimum fill level
(Figure 4, (1)), fill with distilled water
(Figure 4, (2)) (available in the market)
up to the upper limit (Figure 4, (3)) of the
battery. (Battery fluid tends to evaporate
in high temperatures, especially in
• ALWAYS be environmentally summer. In such cases, inspect the
responsible. battery earlier than specified.)
• Follow the guidelines of the 2. If the starter rpm is too low and the
EPA or other governmental engine cannot be started, measure the
agencies for the proper specific gravity of the battery with a
disposal of hazardous hydrometer.
diesel fuel and engine coolant. When the specific gravity of the fluid is
Consult the local authorities or over 1.27 at 20°C (68°F), it is fully
reclamation facility. charged. Fluid with a specific gravity of
below 1.24 needs charging. If the
• NEVER dispose of hazardous specific gravity cannot be raised by
materials irresponsibly by charging, the battery must be replaced.
the ground or into ground Note: The capacities of the standard
water or waterways. alternator and the
recommended battery assume
• Failure to follow these
only the power necessary for
procedures may seriously
regular operation. If the power is
harm the environment.
also used for inboard lighting or
0000013en
other purposes, the generating
and charging capacities may be
insufficient. In such cases, see
your authorized Yanmar marine
dealer or distributor.
2
3
1
0002388
Figure 4
1. Do not operate engine if battery has
insufficient battery fluid as the battery
will be destroyed.

Adjust Alternator V-Belt 2
Tension
When there is not enough tension in the
V-belt, it will slip and the fresh water pump
will fail to supply coolant. Engine
overheating and seizure will result.
When there is too much tension in the 1
3
V-belt, the belt will become damaged more
quickly and the fresh water pump bearing
may be damaged.
0002077A
A WARNING
Figure 5
1. Check the tension of the V-belt by
pressing on the middle of the belt
(Figure 5, (1)) with your finger
SEVER HAZARD! approximately 98N, 10kgf (22 lbf).
• Stop the engine before you With proper tension, the V-belt should
begin to service it. deflect 8 - 10 mm (0.315 - 0.393 in).
• ALWAYS turn off the battery
switch when you are servicing 2. If the V-belt deflection is out of the limit,
the engine. Someone may adjust the V-belt tension. Loosen the
accidentally start the engine adjuster bolt (Figure 5, (2)) and move
and not realize you are the alternator (Figure 5, (3)) to adjust
servicing it. This could result the V-belt tension.
in a serious injury.
CAUTION
• If you must service the engine
while it is operating, remove all Be careful not to get any oil on
jewelry, tie back long hair, and the V-belt. Oil on the belt causes
keep your hands, other body slipping and stretching. Replace
parts and clothing away from the belt if it is damaged.
moving / rotating parts.
3. If the V-belt is damaged or worn,
• Failure to comply could result replace it. Loosen the adjuster bolt
in death or serious injury. (Figure 5, (2)) and move the alternator
0000010en6LY3 (Figure 5, (3)). Remove belt from
pulleys.
4. Install new belt per routing (Figure 5)
and adjust the tension as shown in
Step 2.

Check the Fuel Injector Spray
Every 250 Hours of Operation Pattern
Inspection and adjustment are necessary
Perform the following maintenance every to obtain optimal fuel injection to ensure
250 hours or one year of operation, the best possible engine performance.
whichever comes first. This inspection requires specialized
• Check Fuel Injector Spray Pattern knowledge and techniques. See your
• Adjust Intake / Exhaust Valve distributor to check the injection spray
Clearance (1st Time) condition.
• Drain the Fuel Tank
• Replace the Fuel Filter Element Clearance (1st Time)
• Replace the Engine Oil (Crankcase) Inspection and adjustment must be made
to correct opening / closing timing lags of
• Replace the Engine Oil Filter Element
the intake / exhaust valves which might
• Check the Seawater Pump Impeller arise due to initial parts wear. This
inspection requires specialized knowledge
• Replace the Anode
and techniques. See your authorized
• Clean the Air Intake Silencer Yanmar marine dealer or distributor to
adjust the intake / exhaust valve clearance.
• 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

Drain the Fuel Tank
CAUTION
A DANGER
FIRE AND EXPLOSION • ALWAYS be environmentally

HAZARD! responsible.
• Diesel fuel is flammable and • Follow the guidelines of the
explosive under certain EPA or other governmental
conditions. agencies for the proper
disposal of hazardous
• When you remove any fuel
system component to perform
diesel fuel and engine coolant.
maintenance (such as
Consult the local authorities or
changing the fuel filter) place
reclamation facility.
the opening to catch the fuel. • NEVER dispose of hazardous
the fuel. Vapors from the rag
water or waterways.
• Failure to follow these
immediately.
procedures may seriously
• Wear eye protection. The fuel harm the environment.
system is under pressure and 0000013en
fuel could spray out when you
remove any fuel system Position an approved container under the
component. fuel tank drain. Open the drain cock and let
• Failure to comply will result in the water, dirt, etc. drain from the tank's
death or serious injury. bottom into the container. Drain until fuel
with no water and dirt flows out. Close the
0000009en
drain cock. See Filling the Fuel Tank on
page 41.

Replace the Fuel Filter Element Replace the Engine Oil
When the engine is operated on light (Crankcase)
diesel oil, replace the fuel filter element See Replace Engine Oil and Engine Oil
every 250 hours or one year of operation. Filter on page 96.
1. Close the fuel tank drain cock. Replace the Engine Oil Filter
2. Remove the center bolt (Figure 6, (1)) Element
at the bottom of the filter and take out
See Replace Engine Oil and Engine Oil
the filter element (Figure 6, (2)).
Filter on page 96.
3. Replace the element with a new one
and tighten the center bolt Check the Seawater Pump
(Figure 6, (1)). Impeller
Depending on use, the inside parts of the
seawater pump deteriorate and discharge
performance drops.
At the specified interval or when the
2 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
1 found, disassembly and maintenance
are necessary:
0002078A
• Impeller blades are cracked or nicked.
• Edges or surfaces of the blades are
Figure 6
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.

If a large amount of water leaks Replace the Anode
continuously from the water drain pipe The timing for replacing anode varies
beneath the seawater pump during depending on the characteristics of the
operation, disassembly and seawater and operational conditions.
maintenance (replacement of the lip
seal) are necessary. Inspect the anode periodically and remove
the corroded area on the surface.
When disassembly and maintenance of
the seawater pump are necessary, see Replace the anode when it has decreased
your Yanmar dealer or distributor. to less than 1/2 of the original volume. If
replacement of anode is neglected and
Note: The seawater pump turns in the operation is continued with a corroded
direction as shown (Figure 7) anode, corrosion of the seawater cooling
and the impeller must be system will occur and water leakage or
installed to run in this direction. parts breakage will result.
If the impeller has been removed
for any reason and must be The label (Figure 8) is stamped on the
reassembled, be very careful not plugs which have the anode.
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 ZINC
twist the impeller and damage it. 0002081
1
Figure 8
Be sure to close the seacock before
removing the plug to replace the anode.
Clean the Air Intake Silencer

Disassemble the intake silencer and clean
the inside thoroughly.
1. Take off the clamp and remove the
2
muffler.
0002080 2. Clean the element with a neutral
Figure 7 detergent.
3. Reassemble after the muffler is
completely dry.

Clean the Exhaust / Water Tighten All Major Nuts and
Mixing Elbow Bolts
The mixing elbow is attached to the After long period of usage, the major nuts
turbocharger. The exhaust gas is mixed and bolts of the engine may loosen.
with seawater in the mixing elbow. Tighten the major nuts and bolts to the
standard tightening torques. This
1. Clean dirt and scale out of the exhaust
inspection requires specialized knowledge
gas passage and seawater way in the
and techniques. See your authorized
mixing elbow.
Yanmar marine dealer or distributor to
2. Repair the crack or damage of the tighten major nuts and bolts.
mixing elbow by welding, or replace if
necessary. Check / Replace the Flexible
3. Inspect the gasket and replace if Engine Mounts
necessary. The rubber tension of the flexible engine
mounts is lost after many hours of use.
Clean the Turbocharger Blower
Contamination of the turbocharger blower This leads to a drop in vibration absorption
causes blower revolutions to drop and performance, and also causes centering
engine output to fall. misalignment of the propeller shaft.
If a drop of engine output is noted (by 1. Check if the rubber is cracked. If

about 10%), clean the blower. This should necessary, replace the flexible mount.
only be done by a trained and qualified 2. Check for abnormal noise or vibration
technician. See your authorized Yanmar while engine is running. If necessary,
marine dealer or distributor to clean the replace the flexible mount.
turbocharger blower.
CAUTION
Flush the Aftercooler
NEVER allow engine oil or diesel
Contamination of the aftercooler causes fuel oil to contact the flexible
the engine output to fall. rubber mount. Oil makes rubber
If a drop of engine output is noted (by deteriorate.
about 10%), flush and clean the 0000155en
aftercooler.
This should be done only by a trained and
qualified technician. See your authorized
flush the aftercooler.
Check the Wiring Connectors

Check for any loose connections.

Replace Engine Coolant
Every 500 Hours of Operation
Cooling performance drops when coolant
is contaminated with rust and scale. The
coolant must be replaced periodically Perform the following maintenance every
because its properties deteriorate over 500 hours or two years of operation,
time. whichever comes first.
To drain the engine coolant, open the fresh • Replace Seawater Pump Impeller
water drain cocks (two places). • Adjust the Propeller Shaft Alignment
See Engine Coolant on page 46 for • Check Alternator Belt Tension
coolant specifications.
• NEVER mix different types and / or
Replace the Seawater Pump
colors of coolants. Impeller
Discard old coolant in an approved manner Replace the used seawater pump impeller
according to environmental laws. 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' 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
distributor to adjust the propeller shaft
alignment.
Check Alternator Belt Tension

Check the alternator belt tension. See
Adjust Alternator V-Belt Tension on
page 103.

Replace Alternator Belt
Every 1000 Hours of Operation
Replace the alternator belt with a new one
every 1000 hours or four years, whichever
Perform the following maintenance every comes first, even if there is no crack or
1000 hours or four years of operation, damage in the surface.
See Adjust Alternator V-Belt Tension on
• Check the Fuel Injector Spray Pattern page 103.
• Clean and Check the Water Passages
• Replace Alternator Belt Clearance
• Adjust Intake / Exhaust Valve Proper adjustment is necessary to
Clearance maintain the correct timing for opening and
closing the valves. Improper adjustment
• Replace Flexible Engine Mounts
will cause the engine to run noisily,
Check the Fuel Injector Spray resulting in poor engine performance and
engine damage. See your authorized
Pattern
Adjustment is necessary to obtain the adjust the intake / exhaust valve clearance.
optimal fuel injection to ensure the best
possible engine performance. Replace Flexible Engine
This inspection requires specialized Mounts
knowledge and techniques. See your Be sure to replace the Yanmar flexible
authorized Yanmar marine dealer or engine mounts every 1000 hours or 4
distributor to check the injection spray years, whichever comes first.
condition.
The rubber tension of the flexible engine
Clean and Check the Seawater mounts is lost after many hours of use.
This leads to a drop in vibration absorption
Passages
performance, and also causes centering
When it is used for a long time, cleaning misalignment of the propeller shaft.
the seawater passages is periodically
necessary because trash, scales, rust, and
so on collect in the seawater passages and
the cooling performance declines.
knowledge. See your authorized Yanmar
marine dealer or distributor to clean and
check the water passages.

Relevant Coolant System Parts:
Every 2000 Hours of Operation Seawater pump, engine oil cooler,
aftercooler, fresh water pump, fresh water
Perform the following maintenance every cooler, thermostat, etc.
2000 hours or eight years of operation,
See your authorized Yanmar marine dealer
or distributor to clean the seawater and
• Overhaul and Check Fuel Feed Pump engine coolant systems.
• Clean Engine Oil Cooler Replace Rubber Fuel Hoses
• Clean Seawater and Engine Coolant Rubberized fuel hoses tend to dry out and
System become brittle after 2000 hours or 8 years
• Replace Rubber Fuel Hoses of engine operation (whichever comes
first).
Overhaul and Check Fuel Feed See your authorized Yanmar marine dealer
Pump or distributor to replace the rubber fuel
Fuel feed pump must be overhauled and hoses.
checked to ensure optimal engine
performance.
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.
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.

EPA REQUIREMENTS
The EPA emission regulation is applicable The following are the conditions that must
only in USA. be met in order to ensure that the
emissions during operation meet the EPA
EPA Certification Plates standards. Be sure to follow these:
The engine has the EPA Certification
The operating conditions should be as
Plates (emission control label and
follows:
recreational marine engine label) attached.
1. Ambient temperature: -20 - 40°C
Those labels are attached to the top of the
(-4 - 104°F)
electronic control unit (ECU) cover plate
(Figure 9). 2. Relative humidity: 80% or lower
3. Permissible value for intake negative
pressure: 3.9 kPa (400 mmAq) or lower
4. Permissible value for exhaust back
pressure: 19.6 kPa (2000 mmAq) 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
Be sure to perform inspections as outlined
in Periodic Maintenance Procedures on
page 96 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
0003493
cleaner)
Figure 9
Note: Inspections are divided into two
Conditions to Ensure sections in accordance with who
is responsible for performing the
Compliance with EPA Emission
inspection: the user or the
Standards maker.
This product is an EPA-approved engine.

Inspection and Maintenance
See Inspection and Maintenance of EPA
Emission-Related Parts on page 95 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 93.
This maintenance must be performed to
keep the emission values of your engine in
the standard values 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 123.


Back
TROUBLESHOOTING
If a problem occurs, stop the engine
immediately. Refer to the SYMPTOM
column in the Troubleshooting Chart to
identify the problem.
CAUTION CAUTION
If the alarm window with audible If any alarm indicator with
alarm fails to display and go out audible alarm sound appears on
about three seconds later when the display during engine
the rocker switch is pushed to operation, stop the engine
the ON position, see your immediately. Determine the
authorized Yanmar marine dealer cause and repair the problem
or distributor for service before before you continue to operate
operating the engine. the engine.
0000028enMarine 0000029en6LY3

TROUBLESHOOTING Back
TROUBLESHOOTING CHART
Symptom Probable Cause Measure Reference
Alarm indicators and Shift to low speed operation immediately, and check which indicator has come on
alarm sound come on in in the display. Stop the engine for inspection. If no abnormality is identified and
the display during there is no problem with operation, return to the port at lowest speed and request
operation. repairs.
• Lube oil low pressure • Engine lube oil level is low. • Check lube oil level. Checking Engine
alarm indicator comes Add or replace. Oil on page 45
on.
• Lube oil filter clogged. • Replace lube oil filter. Replace Engine
Replace lube oil. Oil and Engine Oil
Filter on page 96
• Marine gear lube oil • Marine gear lube oil is low. • Check the oil level and
pressure alarm supply. —
indicator comes on.
• Coolant high • Coolant/fresh water in coolant • Check coolant level Check Diesel
temperature alarm tank is low. and replenish. Fuel, Engine Oil,
indicator comes on.
and Engine
Coolant Levels on
page 52
• Insufficient seawater causing • Check seawater
—
temperature to rise. system.
• Contamination inside cooling • See your authorized
system. Yanmar marine dealer —
or distributor.
Do not operate the engine if alarm devices are not repaired. Serious accidents may
Faulty Warning Devices
result if difficulties are not spotted due to faulty alarm lamps.
(1) When switch is turned ON:
• Alarm buzzer sounds. • Circuit broken. • See your authorized
Note: Alarm buzzer only sounds Yanmar marine dealer —
when there is an abnormality. or distributor.
• Alarm indicator comes • Circuit broken. • See your authorized
on. Note: Alarm indicator only comes Yanmar marine dealer —
on when there is an abnormality. or distributor.
(2) When the rocker switch returned to ON from START after engine starts:
• Buzzer keeps on • Sensor switches faulty - if • See your authorized
sounding. indicator does not come on. Yanmar marine dealer
—
• Short-circuit - if indicator does or distributor.
not come on.
• One of the alarm • Sensor switches engine faulty. • See your authorized
indicators comes on. Yanmar marine dealer —
or distributor.
• Battery low charge • V-belt is loose or broken. • Replace V-belt; adjust Adjust Alternator
indicator comes on tension. V-Belt Tension on
during operation.
page 103
• Battery defective. • Check battery fluid Check the
level, specific gravity. Battery on
Replace. page 101
• Alternator power generation • See your authorized
failure. Yanmar marine dealer —
or distributor.

Back TROUBLESHOOTING
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 Back

Back
LONG-TERM
STORAGE
BEFORE YOU PLACE THE CAUTION

ENGINE IN LONG-TERM If seawater is left inside of the
STORAGE engine, it may freeze and
In cold temperatures or before long-term
storage, be sure to drain the seawater from
temperature is below 0°C (32°F).
the cooling system.
0000154en
A WARNING
BURN HAZARD!
0000016en

LONG-TERM STORAGE Back
1. Loosen the seawater drain cocks Before placing the engine in storage,
(Figure 1, (1)) and (Figure 2, (1)) and perform the following:
drain the seawater.
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. See Filling Heat Exchanger
with Engine Coolant on page 48.
0002064
4. Cover the turbocharger, exhaust pipe,
1 etc. with vinyl sheets and seal them to
Figure 1 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.
1
0002072
RETURNING THE ENGINE

Figure 2 TO SERVICE
If no liquid comes from the drain cocks, it 1. Replace the engine oil and engine oil
may be necessary to use a stiff wire to filter before running the engine.
remove any debris to allow drainage. 2. Supply fuel if the fuel in the fuel tank
was removed, and prime the fuel
2. Loosen the 6 bolts attaching the side system.
cover of the seawater pump, remove
3. Confirm that there is engine coolant in
the cover and drain the water from
the engine.
inside.
4. Operate the engine at idle speed for
Retighten the bolts when finished.
one minute.
3. Close the drain cocks. 5. Check fluid levels and check engine for
Note: Do not drain coolant (fresh water leaks.
cooling system). If the coolant is
drained, the cooling system
components could corrode.

Back
SPECIFICATIONS
PRINCIPAL ENGINE SPECIFICATIONS
Engine Model 6LY3-ETP 6LY3-STP 6LY3-UTP
Use Pleasure Use
Type Vertical water-cooled, 4-cycle diesel engine
Aspiration Turbocharger with Aftercooler
Combustion System Direct injection
Number of Cylinders 6
Bore x Stroke 105.9 × 110 mm (4.17 × 4.33 in)
Displacement 5.813 L (6.14 qt)
Output at Crankshaft 3198 min (rpm)
Continuous Power
Engine / Speed 436 hp Metric 400 hp Metric 345 hp Metric
(Note 1 and Note 2) 321 kW 295 kW 254 kW
3300 min (rpm)
Output at Crankshaft
480 hp Metric 440 hp Metric 380 hp Metric
Fuel Stop Power Engine / Speed
(Note 1 and Note 2) 353 kW 324 kW 279 kW
at fuel inlet temp. 40°C (104°F)
High Idling (Note 3) 3500 ± 25 min (rpm)
Low Idling (Note 3) 700 ± 25 min (rpm)
Installation Flexible mounting
Direction of Rotation Crankshaft Counterclockwise viewed from stern
Cooling System Liquid cooling with heat exchanger
Lubrication System Complete enclosed forced lubrication
Engine: 28 L (30 qt)
Coolant Capacity (Fresh)
Coolant recovery tank: 1.5 L (1.6 qt)
Rake Angle 0°
Engine Lubricating Oil
Total (Note 4) 18.8 L (19.9 qt)
Capacity
Effective (Note 5) 8.0 L (8.5 qt)
121
SPECIFICATIONS Back
Engine Model 6LY3-ETP 6LY3-STP 6LY3-UTP
Type Electric
Starting System Starting Motor DC 12V - 3kW
AC Generator 12V - 80A
Model RHC7W (IHI made)
Turbocharger
Type Water cooled
Overall Length 1300.4 mm (51.2 in)
Engine Dimension 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 more
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
3. Fuel condition: Density at 15°C (59°F) = 0.860 g/cm3 (53.67 ft·lb3).
4. Fuel temperature at the inlet of the fuel injection pump.
5. The “Total Engine Lubricating Oil Capacity” includes oil in oil pan, channels, coolers
and filter.
6. The “Effective Engine Lubricating Oil Capacity” indicates the difference in maximum
scale of the dipstick and minimum scale.
122
Back
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).
0003493
Figure 1
123
EPA WARRANTY USA ONLY Back
THIS EMISSION WARRANTY APPLIES It is recommended that any replacement
TO THE ENGINES CERTIFIED TO parts used for maintenance, repair or
UNITED STATES EPA 40 CFR 94 AND replacement of emission control systems
SOLD BY YANMAR THAT ARE are Yanmar parts. The owner may elect to
INSTALLED IN VESSELS FLAGGED OR have maintenance, replacement or repair
REGISTERED IN THE UNITED STATES. of the emission control components and
systems performed by any repair
Your Warranty Rights and establishment or individual and may elect
Obligations: to use parts other than Yanmar parts for
Yanmar warrants to the first user and each such maintenance, replacement or repair.
subsequent purchaser the emission However, the cost of such service or parts
control system on your engine for periods and subsequent failures from such service
of time listed below provided the engine or parts will not be covered under this
has been installed according to Yanmar emission control system warranty:
installation requirements and there has
been no abuse, neglect, or improper
Warranty Period:
maintenance of your Yanmar marine The warranty starts on either the date of
engine. delivery to the first end-user, or the date
the unit is first leased, rented, or loaned.
Yanmar warrants that the engine is
designed, built and tested using genuine 1. For Pleasure Use: The warranty period
parts and equipped so as to conform to all is five (5) years or 2000 hours of use,
applicable emission requirements of the whichever occurs first. In the absence
U.S. Environmental Protection Agency and of a device to measure hours of use,
is free from defects in material and the engine as a warranty period of
workmanship which would cause this five (5) years.
engine to fail to conform to the applicable 2. For Commercial Use: The warranty
emission regulations over its limited period is five (5) years or 5000 hours
emission control system warranty period. of use, whichever occurs first. In the
Where a warrantable emissions condition absence of a device to measure hours
exists, Yanmar will repair your engine at no of use, the engine as a warranty period
charge to you for diagnosis, parts, and of five (5) years.
labor. Warranty service or repair will be
provided at authorized Yanmar marine
deals or distributors.
124
Back EPA WARRANTY USA ONLY
Warranty Coverage: Your engine is designed to operate on
diesel fuel only. Use of any other fuel may
Repair or replacement of any warranted
result in your engine no longer operating in
parts will be performed at an authorized
compliance with applicable emission
Yanmar dealer or distributor. This limited
requirements. You are responsible for
emission control system warranty covers
initiating the warranty process. You must
engine components that are a part of the
present your marine engine to an
emission control system of the engine as
authorized Yanmar dealer or distributor as
delivered by Yanmar to the original retail
soon as a problem exists.
purchaser. Such components may include
the following: Customer Assistance:
1. Fuel Injection System If you have any questions regarding your
2. Turbocharger System warranty rights and responsibilities or
would like information on the nearest
3. Aftercooler
authorized Yanmar dealer or distributor,
4. Electronic Engine Control Units and its you should contact Yanmar Marine USA
associated Sensor and Actuators Corporation for assistance.
Exclusions: Yanmar Marine USA Corporation
Failures other than those arising from 101 International Parkway
defects in material and / or workmanship Adairsville, GA 30103
are not covered by this limited emissions USA
warranty. This warranty does not extend to
the following: malfunction caused by Telephone: 770-877-9894
abuse, misuse, improper adjustment, Fax: 770-877-7567
modification, alteration, tampering,
disconnection, improper or inadequate
maintenance, improper storage or use of
non-recommended 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.
125
EPA WARRANTY USA ONLY Back
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ii 6LY3 Operation Manual

6LY3 Operation Manual iii

Engine Model: __________________________________________________________

Engine Serial No.: _______________________________________________________

iv 6LY3 Operation Manual

6LY3 Operation Manual 1

2 6LY3 Operation Manual

6LY3 Operation Manual 3

4 6LY3 Operation Manual

6LY3 Operation Manual 1

2 6LY3 Operation Manual

FIRE AND EXPLOSION

6LY3 Operation Manual 3

FIRE AND EXPLOSION FIRE AND EXPLOSION

4 6LY3 Operation Manual

FIRE AND EXPLOSION

6LY3 Operation Manual 5

FIRE AND EXPLOSION CRUSH HAZARD!

6 6LY3 Operation Manual

6LY3 Operation Manual 7

ALCOHOL AND DRUG

8 6LY3 Operation Manual

6LY3 Operation Manual 9

10 6LY3 Operation Manual

BURN HAZARD! FIRE HAZARD!

6LY3 Operation Manual 11

FLYING OBJECT HAZARD!

12 6LY3 Operation Manual

6LY3 Operation Manual 13

may affect warranty coverage,

14 6LY3 Operation Manual

6LY3 Operation Manual 15

agencies for the proper

16 6LY3 Operation Manual

poor engine performance and

level in the fuel tank, water may

engine and damage it.

6LY3 Operation Manual 17

18 6LY3 Operation Manual

6LY3 Operation Manual 19

This Page Intentionally Left Blank

20 6LY3 Operation Manual

YANMAR 6LY3 FEATURES The engine must be installed correctly with

6LY3 Operation Manual 21

1. Oil Fill Cap 6. Lube Oil Filter

22 6LY3 Operation Manual

1. Coolant Tank (Exhaust Manifold) 5. Alternator

6LY3 Operation Manual 23

LOCATION OF LABELS 128296-07300

Figure 3 shows the location of regulatory

Warning Labels 128296-07260

24 6LY3 Operation Manual

YANMAR DIESEL ENGINE

YANMAR CO., LTD.

6LY3 Operation Manual 25

FUNCTION OF MAJOR COMPONENTS

26 6LY3 Operation Manual

6LY3 Operation Manual 27