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

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This Workshop Service Repair manual PDF download for the 6LY3-ETP, 6LY3-STP & 6LY3-UTP Yanmar Marine Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Yanmar Marine Diesel Engine 6LY3-ETP
Yanmar Marine Diesel Engine 6LY3-STP
Yanmar Marine Diesel Engine 6LY3-UTP

6LY3-UTP : Yanmar Inboard Engine 380hp/279kW - EPB5634
6LY3-STP : Yanmar Inboard Engine 440hp/324kW - EPB5634
6LY3-ETP : Yanmar Inboard Engine 480hp/353kW - EPB5634


TABLE OF CONTENTS :

1. General
2. Inspection and adjustment
3. Troubleshooting
4. Disassembly and reassembly
5. Inspection and servicing of basic engine parts
6. Fuel injection equipment
7. Intake and exhaust system
8. Lubrication system
9. Cooling water system
10. Turbocharger
11. Reduction and reversing gear
12. Remote control
13. Electrical system
14. Service standards
15. Tightening torque for bolts and nuts


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : OBLY3-G00100
Total Pages : 397


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover
History of Revision
FOREWORD
CONTENTS
FOR SAFETY
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 Electronic Control System
3.1.1 Engine control system diagram
3.1.2 Preparation before troubleshooting
3.1.3 Air heater
3.1.4 Fuse, relay and harness
3.2 Troubleshooting
3.2.1 Troubleshooting from trouble symptom
3.2.2 Troubleshooting of fuse
3.3 Trouble code
3.3.1 TELEFLEX i5501E Display "Alarm Screen Information"
3.3.2 ECU Connector Pin Configuration
3.3.3 Abbreviation
3.3.4 List of DTC (Diagnostic Trouble Code)
3.3.5 Diagnosis Procedure of Temperature Sensor
3.3.6 Diagnosis Procedure of Pressure Sensor
3.3.7 Other Wiring Diagram
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)
Colophon
Back cover

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