Yanmar 6LY3-ETP, 6LY3-STP, 6LY3-UTP Service Manual

Description

• Model List:
  • 6LY3-ETP, 6LY3-STP, 6LY3-UTP

• 1. General
• 1.1. Exterior views
• 1.2. Main specifications
• 1.3. Fuel oil, lubricating oil and cooling water
• 1.3.1. Fuel oil
• 1.3.2. Lubricating oil
• 1.3.3. Cooling water
• 1.4. Engine outline
• 1.5. Piping diagrams
• 1.6. Exhaust gas emission regulation
• 1.6.1. Engine identification
• 1.6.2. EPA exhaust gas emission standard
• 1.6.3. EPA guarantee conditions for emission standard
• 2. Inspection and adjustment
• 2.1. Periodic maintenance schedule
• 2.2. Periodic inspection and maintenance procedure
• 2.2.1. Check before starting
• 2.2.2. Inspection after initial 50 hours or one month operation
• 2.2.3. Inspection every 50 hours or monthly
• 2.2.4. Inspection on initial 250 hours or one year
• 2.2.5. Inspection every 250 hours or one year
• 2.2.6. Inspection every year
• 2.2.7. Inspection every 500 hours or two years
• 2.2.8. Inspection 2,000 hours or every two years
• 2.2.9. Inspection every 1,000 hours or four years
• 2.2.10. Inspection every 2000 hours or eight years
• 2.3. Adjusting the no-load minimum speed
• 2.4. Thermostat inspection
• 2.5. Test running
• 2.5.1. Preliminary precautions
• 2.5.2. Test running procedure
• 2.5.3. Check points and precautions during running
• 2.6. Long storage
• 3. Troubleshooting
• 3.1. Preparation before troubleshooting
• 3.2. Troubleshooting
• 3.2.1. Troubleshooting from trouble symptom
• 3.2.2. Troubleshooting of fuse
• 3.3. Trouble code
• 3.3.1. List of DTC (Diagnostic Trouble Code)
• 3.3.2. Temperature / Pressure Sensor Diagnosis
• 3.3.3. Other Wiring Diagram
• 3.3.4. TELEFLEX i5501E Display Alarm Screen Information
• 3.3.5. ECU Connector Pin Configuration
• 3.3.6. Abbreviation
• 4. Disassembly and reassembly
• 4.1. Disassembly and reassembly precautions
• 4.2. Disassembly and reassembly tools
• 4.2.1. General hand tools
• 4.2.2. Special hand tools
• 4.2.3. Measuring instruments
• 4.2.4. Other material
• 4.3. Disassembly and reassembly
• 4.3.1. Disassembly
• 4.3.2. Reassembly
• 5. Inspection and servicing of basic engine parts
• 5.1. Cylinder block
• 5.1.1. Inspection of parts
• 5.1.2. Cleaning of oil holes
• 5.1.3. Color check procedure
• 5.1.4. Replacement of plugs
• 5.1.5. Cylinder bore measurement
• 5.2. Cylinder head
• 5.2.1. Inspecting the cylinder head
• 5.2.2. Valve seat correction procedure
• 5.2.3. Intake / exhaust valves, valve guides
• 5.2.4. Valve springs
• 5.2.5. Nozzle sleeve
• 5.2.6. Assembling the cylinder head
• 5.2.7. Measuring top clearance
• 5.2.8. Intake and exhaust rocker arms
• 5.2.9. Adjustment of valve clearance
• 5.3. Piston and piston pins
• 5.3.1. Piston
• 5.3.2. Piston pin
• 5.3.3. Piston rings
• 5.4. Connecting rod
• 5.4.1. Inspecting the connection rod
• 5.4.2. Crank pin metal
• 5.4.3. Piston pin bushing
• 5.4.4. Assembling piston and connecting rod
• 5.5. Crankshaft and main bearing
• 5.5.1. Crankshaft
• 5.5.2. Main bearing
• 5.6. Camshaft and Tappets
• 5.6.1. Camshaft
• 5.6.2. Tappets
• 5.7. Timing gear
• 5.7.1. Inspecting the gears
• 5.7.2. Gear timing marks
• 5.8. Flywheel and housing
• 5.8.1. Specifications of flywheel
• 5.8.2. Ring gear
• 5.8.3. Position of top dead center
• 6. Fuel injection equipment
• 6.1. Fuel Injection pump / governor / timer
• 6.1.1. Fuel system diagram
• 6.1.2. Fuel injection pump specifications
• 6.1.3. Governor structure and function
• 6.1.4. Timer structure and function
• 6.1.5. Removing a fuel injection pump assembly
• 6.1.6. Installing a fuel injection pump assembly
• 6.1.7. Troubleshooting of fuel injection pump
• 6.2. Fuel Injection nozzle
• 6.2.1. Functioning of fuel injection nozzle
• 6.3. Fuel feed pump
• 6.3.1. Fuel feed pump specifications
• 6.3.2. Fuel feed pump disassembly
• 6.3.3. Fuel feed pump inspection
• 6.3.4. Fuel feed pump reassembly
• 6.3.5. Fuel feed pump adjustment
• 6.4. Fuel filter
• 6.4.1. Fuel filter specifications
• 6.4.2. Fuel filter inspection
• 6.5. Electronic Control System
• 7. Intake and exhaust system
• 7.1. Intake system
• 7.2. Exhaust system
• 7.2.1. Mixing elbow inspection
• 8. Lubrication system
• 8.1. Lubrication system
• 8.2. Lube oil pump
• 8.2.1. Lube oil pump construction
• 8.2.2. Specifications of lube oil pump
• 8.2.3. Lube oil pump disassembly and reassembly
• 8.2.4. Oil pressure control valve construction
• 8.3. Lube oil filter
• 8.3.1. Lube oil filter construction
• 8.3.2. Lube oil filter replacement
• 8.4. Lube oil cooler
• 8.4.1. Lube oil cooler construction
• 8.4.2. Inspecting the lube oil cooler
• 8.5. Rotary waste oil pump (Optional)
• 9. Cooling water system
• 9.1. Cooling water system
• 9.2. Seawater pump
• 9.2.1. Specifications of seawater pump
• 9.2.2. Seawater pump disassembly
• 9.2.3. Seawater pump Inspection
• 9.2.4. Seawater pump reassembly
• 9.3. Fresh water pump
• 9.3.1. Fresh water pump construction
• 9.3.2. Specifications of fresh water pump
• 9.3.3. Fresh water pump disassembly
• 9.3.4. Fresh water pump inspection
• 9.4. Heat exchanger
• 9.4.1. Heat exchanger construction
• 9.4.2. Specifications of heat exchanger
• 9.4.3. Disassembly and reassembly
• 9.4.4. Heat exchanger inspection
• 9.5. Pressure cap and coolant recovery tank
• 9.5.1. Pressure cap construction
• 9.5.2. Pressure cap pressure control
• 9.5.3. Pressure cap inspection
• 9.5.4. Function of the coolant recovery tank
• 9.5.5. Specifications of coolant recovery tank
• 9.5.6. Mounting the coolant recovery tank
• 9.5.7. Precautions on usage of the coolant recovery tank
• 9.6. Thermostat
• 9.6.1. Functioning of thermostat
• 9.6.2. Thermostat construction
• 9.6.3. Characteristics of thermostat
• 9.6.4. Thermostat inspection
• 9.6.5. Testing the thermostat
• 9.7. Seacock (Optional)
• 9.8. Bilge pump and bilge strainer (Optional)
• 9.8.1. Introduction
• 9.8.2. Description
• 9.8.3. Cautions
• 9.8.4. Assembly procedure
• 9.8.5. Cautions for Assembling
• 9.8.6. Troubleshooting
• 10. Turbocharger
• 10.1. Construction and function
• 10.1.1. Outline
• 10.2. Standards for maintenance and check
• 10.2.1. Standards for maintenance and check
• 10.2.2. Tightening torque
• 10.3. Periodical checking procedure
• 10.3.1. Periodical checking interval
• 10.3.2. Checking procedure
• 10.4. Disassembly procedure
• 10.4.1. Preparations for disassembly
• 10.4.2. Check before disassembly
• 10.4.3. Disassembly
• 10.5. Cleaning and checking procedure
• 10.5.1. Cleaning
• 10.5.2. Checking procedure
• 10.6. Reassembling procedure
• 10.6.1. Preparations for reassembly
• 10.6.2. Reassembling procedure
• 10.7. Handling after reassembly
• 10.7.1. Precautions for mounting the turbocharger to the engine
• 10.8. Troubleshooting
• 10.8.1. Exhaust gas is dense
• 10.8.2. Whitish exhaust gas
• 10.8.3. Too early oil shortage
• 10.8.4. Output drop
• 10.8.5. Poor follow-up of supercharger
• 10.8.6. Unusual sound or vibration
• 11. Reduction and reversing gear
• 12. Remote control
• 12.1. Electronic control system (ECS)
• 12.1.1. Digital display
• 12.1.2. Rocker switch panel
• 12.1.3. Control head (Shift Throttle)
• 13. Electrical system
• 13.1. Electrical system
• 13.1.1. Wiring diagram
• 13.2. Battery
• 13.2.1. Construction
• 13.2.2. Battery capacity and battery cables
• 13.2.3. Inspection
• 13.2.4. Charging
• 13.2.5. Battery storage precautions
• 13.3. Starting Motor
• 13.3.1. Specifications
• 13.3.2. Characteristics
• 13.3.3. Structure
• 13.3.4. Wiring diameter of a starting motor
• 13.4. Alternator standard, 12V/80A
• 13.4.1. Specifications
• 13.4.2. Structure
• 13.4.3. Wiring diagram
• 13.4.4. Standard output characteristics
• 13.4.5. Inspection
• 13.5. Warning devices
• 13.5.1. Sensor installation position
• 13.5.2. Lube oil pressure sensor and boost sensor
• 13.5.3. Temperature sensor for water, lube oil and fuel
• 13.6. Air heater
• 13.7. Fuse, relay and harness
• 14. Service standards
• 14.1. Engine tuning
• 14.2. Engine body
• 14.2.1. Cylinder head
• 14.2.2. Camshaft and gear train
• 14.2.3. Cylinder block
• 15. Tightening torque for bolts and nuts
• 15.1. Main bolt and nut
• 15.2. Standard bolts and nuts (without lube oil)