Yanmar 6SY Series Operation Manual Download Page 69

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PERIODIC MAINTENANCE

6SY Operation Manual

DANGER

FIRE AND EXPLOSION

HAZARD!

• Diesel fuel is flammable and

explosive under certain
conditions.

• When you remove any fuel

system component to perform
maintenance (such as
changing the fuel filter) place
an approved container under
the opening to catch the fuel.

• NEVER use a shop rag to catch

the fuel. Vapors from the rag
are flammable and explosive.

• Wipe up any spills

immediately.

• Wear eye protection. The fuel

system is under pressure and
fuel could spray out when you
remove any fuel system
component.

• Failure to comply will result in

death or serious injury.

0000009en

DANGER

FIRE AND EXPLOSION

HAZARD!

• Diesel fuel is flammable and

explosive under certain
conditions.

• NEVER use diesel fuel as a

cleaning agent.

• Failure to comply will result in

death or serious injury.

0000012en

DANGER

FIRE AND EXPLOSION

HAZARD!

• Diesel fuel is flammable and

explosive under certain
conditions.

• NEVER remove the fuel cap

with the engine running.

• Failure to comply will result in

death or serious injury.

0000011en

Summary of Contents for 6SY Series

Page 1: ...6SY series OPERATION MANUAL 6SY Operation Manual P N 0A6301 G0000 MARINE ENGINES ...

Page 2: ...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 ...

Page 3: ...u operate the machine to ensure that you follow safe operating practices and maintenance procedures Keep this Operation Manual in a convenient place for easy access If this Operation Manual is lost or damaged order a new one from your authorized Yanmar marine dealer or distributor Make sure this manual is transferred to subsequent owners This manual should be considered a permanent part of the eng...

Page 4: ...re Engine Model __________________________________________________________ Engine Serial No _______________________________________________________ Date Purchased _________________________________________________________ Dealer _________________________________________________________________ Dealer Phone ___________________________________________________________ ...

Page 5: ...t Overview 19 Yanmar 6SY Features and Applications 19 NamePlate 21 Engine Nameplate Typical 21 Engine Management System EMS S6 23 Rotation Speeds 24 Redundant Throttle Mode 24 Coolant Temperature 24 Oil Pressure 25 Before You Operate 27 Diesel Fuel 33 Diesel Fuel Specifications 33 Additional Technical Fuel Requirements 33 Diesel Fuel Lines 34 Filling the Fuel Tank 34 Bleeding the Fuel System 36 ...

Page 6: ...ne Oil and Engine Coolant Levels 45 Checking and Refilling Marine Gear Oil 45 Checking the Battery Electrolyte Level 45 Checking the Alternator Belt 45 Checking the Alarm Indicators 45 Preparing Fuel Oil and Coolant in Reserve 45 Engine Operation 47 Starting Engine 57 Starting at Low Temperatures 57 Shutting Down the Engine 57 Checking the Engine After Operation 58 Periodic Maintenance 59 Safety P...

Page 7: ...Oil Filter Element 81 Clean the Centrifugal Engine Oil Cleaner 83 Functional Inspection 85 Check and Adjust the Alternator Belt 86 Check Electronic Management System EMS Operation 86 Adjust Propeller Shaft Alignment 86 Replace the Closed Crankcase Ventilation Filter Element 87 Every 50 Hours of Operation 89 Drain or Replace the Fuel Filter Element and Fuel Filter Water Separator 89 Check the Batte...

Page 8: ...ump Impeller Engines with Heat Exchanger 104 Every 1000 Hours of Operation 105 Check the Unit Injector Spray Pattern 105 Adjust Unit Injectors 105 Replace Flexible Engine Mounts 105 Every 2000 Hours of Operation 105 Overhaul and Check Fuel Feed Pump 105 Clean Engine Oil Cooler 105 Check the Battery Charge 106 Replace the Battery 107 Check for Leakage of Fuel Engine Oil and Engine Coolant 108 Clean...

Page 9: ...o it make sure you order the new part and label at the same time A This safety alert symbol appears with most safety statements It means attention become alert your safety is involved Please read and abide by the message that follows the safety alert symbol A DANGER Danger the word DANGER is in white letters with a red rectangle behind it indicates an imminently hazardous situation which if not av...

Page 10: ...t can cause damage to the engine personal property and or the environment or cause the engine to operate improperly 0000001enMarine CAUTION NEVER permit anyone to install or operate the engine without proper training Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures Safety signs and label...

Page 11: ...is running or battery is charging Failure to comply will result in death or serious injury 0000003en A DANGER SCALD HAZARD NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will escape and seriously burn you Allow the engine to cool sufficiently before attempting to remove the filler cap Securely tighten the filler cap after checking the coolant level Steam can ...

Page 12: ...Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER use diesel fuel as a cleaning agent Failure to comply will result in death or serious injury 0000012en A DA...

Page 13: ...sive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric source well away when refueling NEVER overfill the fuel tank Fill the fuel tank Store any c...

Page 14: ... fuel lines tend to dry out and become brittle after two years or 2000 hours of engine operation whichever comes first Failure to comply will result in death or serious injury 0000015en A DANGER EXPLOSION HAZARD NEVER check the remaining battery charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use a hydrometer to check the remaining battery charge...

Page 15: ...rt Failure to comply will result in death or serious injury 0000016en A DANGER CRUSH HAZARD ALWAYS use the engine lifting eyes when lifting the marine engine The lifting eyes are engineered to lift the weight of the marine engine only ALWAYS use lifting equipment with sufficient capacity to lift the marine engine Additional equipment is necessary to lift the marine engine and marine gear together ...

Page 16: ...gine is operating Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002enMarine A WARNING EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vents or o...

Page 17: ...es work shoes eye and hearing protection as required by the task at hand NEVER wear jewelry unbuttoned cuffs ties or loose 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 NEVER operate the engine while wearing a headset to listen to music or r...

Page 18: ... skin immediately flush the affected area with a large amount of clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury 0000007en A WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious i...

Page 19: ... Turn off the battery switch if equipped or disconnect the negative battery cable and the leads to the alternator when welding on the vessel Remove the multi pin connector to the engine control unit Connect the weld clamp to the component to be welded and as close as possible to the welding point NEVER connect the weld clamp to the engine or in a manner which would allow current to pass through a ...

Page 20: ...ly could result in death or serious injury 0000010en A WARNING BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en A WARNING BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye pr...

Page 21: ...ystems can cause an electrical fire Failure to comply could result in death or serious injury 0000027en A CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle Long Life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005enMarine A CAUTION FLYING OBJECT ...

Page 22: ...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 CAUTION The illustrations and descriptions of optional equipment in this manual such as the operator s console are for a typical engine installation Refer to the documentation supplied by the optional equipment manufacturer for specific operation and maintenance inst...

Page 23: ...ses that exceed the design specifications 0000065enMarine CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating engine coolant Carefully clean the heat exchanger cap and the surrounding area before you remove the cap NEVER mix different types ...

Page 24: ...d on a level surface If a Yanmar Marine Engine is installed at an angle that exceeds the specifications stated in the Yanmar Marine Installation manuals engine oil may enter the combustion chamber causing excessive engine speed white exhaust smoke and serious engine damage This applies to engines that run continuously or those that run for short periods of time 0000010enMarine CAUTION Be careful n...

Page 25: ...er to clean the engine 0000014en CAUTION If any indicator fails to illuminate when the key switch is in the ON position see your authorized Yanmar marine dealer or distributor for service before operating the engine 0000028enMarine CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the required periodic maintenance at intervals indicated Fai...

Page 26: ...r has drained out 0000025en CAUTION When the engine is operated in dusty conditions clean the air cleaner element more frequently NEVER operate the engine with the air cleaner or element s removed This may allow foreign material to enter the engine and damage it 0000026en CAUTION Clean or replace the air cleaner element if the air intake restriction exceeds the value listed in the Operation and Se...

Page 27: ...ctrical wiring Any auxiliary equipment attached to the engine should be easy to use and accessible for service To handle the drive equipment propulsion systems including the propeller and other onboard equipment always observe the instructions and cautions given in the operation manuals supplied by the shipyard and equipment manufacturers The laws of some countries may require hull and engine insp...

Page 28: ... Coolant Recovery Tank 4 Engine Oil Fill Cap 5 Engine Number Stamped into the Engine Block 6 Nameplate 7 Coolant Pump 8 Coolant Drain 9 Engine Oil Filter 10 Engine Oil Cleaner 11 Engine Oil Dipstick 12 Engine Oil Drain 13 Heat Exchanger 14 Seawater Outlet 15 Seawater Supply 16 Seawater Pump 17 Charge Air Cooler 18 Close Crankcase Ventilation 19 Turbocharger 20 Fuel Filter 21 Fuel Pump 22 Starter M...

Page 29: ...MEPLATE The following figure Figure 2 shows the location of regulatory and safety labels on Yanmar 6SY marine engines Engine Nameplate Typical 6SY Engines Figure 2 MODEL CONT RATING kW rpm rpm MAX OUTPUT kW ENGINE NO YANMAR DIESEL ENGINE 0003496 ...

Page 30: ...peller Coolant Fill Cap The fill cap on the coolant tank has a pressure regulating valve When the coolant temperature rises the pressure rises inside the fresh water system Coolant Recovery Tank The pressure regulating valve releases vapor and hot water overflow to the coolant recovery tank When the engine stops and the coolant cools the pressure in the coolant tank drops The fill cap valve then o...

Page 31: ... operating conditions The EMS system sensors are also used to send signals to the digital display in the instrument panel The control unit constantly checks the sensors to make sure they are operational The control unit contains monitoring functions to protect the engine in the event of a fault which would otherwise damage it In the event of a fault an alarm for low oil pressure or high coolant te...

Page 32: ... second the S6 control will send a CAN message which activates a warning If the temperature exceeds 103 C 217 F a warning is activated A fault code is generated in the control unit After an alarm approved values must be registered for more than two seconds before resetting the alarm Excessively high coolant temperature can damage the engine If run for extended periods under an extremely light load...

Page 33: ...l pressure of less than 2 3 bar 33 psi for longer than five seconds The following functions are available if there is an alarm Alarm which only switches on a warning Alarm which switches on a warning and reduces torque if this function is activated 70 of fuel quantity A fault code is generated in the control unit After an alarm approved values must be registered for more than two seconds before re...

Page 34: ...PRODUCT OVERVIEW 26 6SY Operation Manual This Page Intentionally Left Blank ...

Page 35: ...out CAUTION NEVER permit anyone to install or operate the engine without proper training Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures Safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized Yanmar marine dealer or distributor...

Page 36: ...000002enMarine A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sparks open flames or any other form of ignition match cigarette static electric source ...

Page 37: ...mable material such as oil hay or dried grass close to the engine during engine operation or shortly after shut down Failure to comply will result in death or serious injury 0000014en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours ...

Page 38: ...ed port Failure to comply will result in death or serious injury 0000016en A WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If you are exposed to high pressure fuel spray obtain prompt medical treatment NEVER check for a fue...

Page 39: ...ly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failure to comply could result in death or serious injury 0000015en A WARNING BURN HAZARD Wait until the engine cools before you drain the engine coolant Hot engine coolant may splash and burn you Failure to comply could result in death or serious injury 0000016en A CAUTION...

Page 40: ...taminating engine oil Carefully clean the oil cap dipstick and the surrounding area before you remove the cap NEVER mix different types of 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 CAUTION Only use the engine coolant specified Other engine coolants may ...

Page 41: ...and fuel handling equipment clean at all times Poor quality fuel can reduce engine performance and or cause engine damage Fuel additives are not recommended Some fuel additives may cause poor engine performance See your authorized Yanmar marine dealer or distributor for more information Ash content not to exceed 0 01 by volume Carbon residue content not to exceed 0 35 by volume Less than 0 1 is pr...

Page 42: ...proximately 50 mm 1 96 in 8 Fuel Shutoff Valve 9 Less than 500 mm 19 68 in 10 To Fuel Injection Pump A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep sp...

Page 43: ...injury 0000014en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines tend to dry out and become brittle after two years or 2000 h...

Page 44: ...SION HAZARD Diesel fuel is extremely flammable and explosive under certain conditions When you prime the fuel system operate the fuel priming lever of the mechanical fuel pump several times until the fuel filter cup is filled with fuel NEVER open the air vent valve while the fuel system is being primed The fuel filter has an internal air bleed port Failure to comply will result in death or serious...

Page 45: ...Open the bleeder valves again and operate the hand pump until fuel without air bubbles flows out Tighten the bleeder valves Start the engine and check for leaks ENGINE OIL CAUTION NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat 0000007en CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal eng...

Page 46: ...er the first 50 hours of operation and then at every 250 hours thereafter 3 Select the oil viscosity based on the ambient temperature where the engine is being operated See the SAE Service Grade Viscosity Chart Figure 3 4 Yanmar does not recommend the use of engine oil additives Additional Technical Engine Oil Requirements The engine oil must be changed when the Total Base Number TBN has been redu...

Page 47: ...p Figure 4 Note The specified angle may only occur intermittently Figure 4 Checking Engine Oil 1 Make sure engine is level 2 Remove dipstick Figure 5 1 and wipe with clean cloth 3 Fully reinsert dipstick 4 Remove dipstick The oil level should be between upper Figure 5 2 and lower Figure 5 3 lines on the dipstick 5 Fully reinsert dipstick Figure 5 24 26 35 35 25 25 2 3 1 ...

Page 48: ...OOLANT CAUTION NEVER overfill the engine with engine oil ALWAYS keep the oil level between upper and lower lines on the oil cap dipstick 0000015en A DANGER SCALD HAZARD NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will escape and seriously burn you Allow the engine to cool sufficiently before attempting to remove the filler cap Securely tighten the filler c...

Page 49: ...0 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 A CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle Long Life engine coolant If contact with the eyes or skin should occur flush eyes and wash imm...

Page 50: ...ecking the Coolant Level A DANGER SCALD HAZARD NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will escape and seriously burn you Allow the engine to cool sufficiently before attempting to remove the filler cap Securely tighten the filler cap after checking the coolant level Steam can escape during engine operation if the cap is loose Failure to comply will re...

Page 51: ...Failure to comply may result in minor or moderate injury 0000005enMarine CAUTION COOLANT HAZARD When adding large amounts of coolant NEVER pour cold coolant into a hot engine The cylinder block and cylinder head could crack 00000029 CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life...

Page 52: ...u have to drain the fuel 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 93 A WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a broken fuel injection line High pressure fuel can penetrate your skin and result in serious injury If yo...

Page 53: ...el before use See Check the Battery Electrolyte Level Servicable Batteries Only on page 91 Checking the Alternator Belt Be sure to check the belt tension before use See Check and Adjust the Alternator Belt on page 86 Checking the Alarm Indicators Check the instruments and alarm indicators at regular intervals Preparing Fuel Oil and Coolant in Reserve Prepare sufficient fuel for the day s operation...

Page 54: ...BEFORE YOU OPERATE 46 6SY Operation Manual This Page Intentionally Left Blank ...

Page 55: ...N NEVER permit anyone to install or operate the engine without proper training Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures Safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized Yanmar marine dealer or distributor for addit...

Page 56: ...ury 0000002enMarine A DANGER EXPLOSION HAZARD Keep the area around the battery well ventilated While the engine is running or the battery is charging hydrogen gas is produced which can be easily ignited Keep sparks open flame and any other form of ignition away while the engine is running or battery is charging Failure to comply will result in death or serious injury 0000003en A DANGER FIRE AND EX...

Page 57: ...pen flames or any other form of ignition match cigarette static electric source well away when refueling NEVER overfill the fuel tank Fill the fuel tank Store any containers containing fuel in a well ventilated area away from any combustibles or sources of ignition Failure to comply will result in death or serious injury 0000005en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and exp...

Page 58: ...hut down Failure to comply will result in death or serious injury 0000014en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Before you operate the engine check for fuel leaks Replace rubberized fuel hoses every two years or every 2000 hours of engine operation whichever comes first even if the engine has been out of service Rubberized fuel lines t...

Page 59: ...the engine is operating Check before starting the engine that any tools or shop rags used during maintenance have been removed from the area Failure to comply could result in death or serious injury 0000002enMarine A WARNING EXHAUST HAZARD NEVER operate the engine in an enclosed area such as a garage tunnel underground room manhole or ship s hold without proper ventilation NEVER block windows vent...

Page 60: ... work shoes eye and hearing protection as required by the task at hand NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing when you are working near moving rotating parts such as the cooling fan flywheel or PTO shaft ALWAYS tie back long hair when you are working near moving rotating parts such as a cooling fan flywheel or PTO shaft NEVER operate the engine while wearing a headset t...

Page 61: ...the damage Failure to comply could result in death or serious injury 0000008enMarine A WARNING BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011en A WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces...

Page 62: ...ilure to comply may result in minor or moderate injury 0000005enMarine CAUTION Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in extremely dusty conditions Avoid operating in the presence of chemical gases or fumes 0000003enMarine CAUTION Only use diesel fuels recommended by Yanmar for the best engine performa...

Page 63: ...0000007en CAUTION NEVER use an engine starting aid such as ether Engine damage will result 0000009en CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of rust and scale and or shorten engine life Prevent dirt and debris from contaminating engine coolant Carefully clean the heat exchanger cap and the surrounding area before yo...

Page 64: ...tributor if the engine will be operated in either temperature extreme See your authorized Yanmar 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 Clean or replace the air cleaner element if the air intake restriction exceeds ...

Page 65: ...see that there are no active faults 2 Push the OFF switch if equipped or turn the key switch to OFF Use the emergency stop switch if equipped only in an emergency 3 Turn the battery master switch if equipped OFF 4 Close the fuel tank cock 5 Close the seacock if equipped CAUTION NEVER hold the key in the START position for longer than 15 seconds or the starter motor will overheat 0000007en CAUTION ...

Page 66: ...rea around the fill opening are clean to avoid contamination of the fuel Turn off the inlet valve seacock for the seawater system if equipped If there is a risk of freezing check that the closed coolant system contains enough glycol See Engine Coolant Specifications on page 41 If there is a risk of freezing empty the seawater system At temperatures below 0 C 32 F drain seawater system and connect ...

Page 67: ...ER permit anyone to install or operate the engine without proper training Read and understand this Operation Manual before you operate or service the engine to ensure that you follow safe operating practices and maintenance procedures Safety signs and labels are additional reminders for safe operating and maintenance techniques See your authorized Yanmar marine dealer or distributor for additional...

Page 68: ... engine is running or battery is charging Failure to comply will result in death or serious injury 0000003en A DANGER SCALD HAZARD NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will escape and seriously burn you Allow the engine to cool sufficiently before attempting to remove the filler cap Securely tighten the filler cap after checking the coolant level St...

Page 69: ...iately Wear eye protection The fuel system is under pressure and fuel could spray out when you remove any fuel system component Failure to comply will result in death or serious injury 0000009en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions NEVER use diesel fuel as a cleaning agent Failure to comply will result in death or serious injury 0000012...

Page 70: ...ou causing serious injury or death Failure to comply will result in death or serious injury 0000008en A DANGER FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions Only fill the fuel tank with diesel fuel Filling the fuel tank with gasoline may result in a fire and will damage the engine NEVER refuel with the engine running Wipe up all spills immediately Keep s...

Page 71: ...berized fuel lines tend to dry out and become brittle after two years or 2000 hours of engine operation whichever comes first Failure to comply will result in death or serious injury 0000015en A DANGER EXPLOSION HAZARD NEVER check the remaining battery charge by shorting out the terminals This will result in a spark and may cause an explosion or fire Use a hydrometer to check the remaining battery...

Page 72: ...R NEVER start the engine unless the air filter is installed Failure to comply will result in death or serious injury 0000025en A WARNING SEVER HAZARD Keep hands and other body parts away from moving rotating parts such as the flywheel or PTO shaft Wear tight fitting clothing and keep your hair short or tie it back while the engine is running Remove all jewelry before you operate or service the eng...

Page 73: ...ust system Failure to comply could result in death or serious injury 0000003en A WARNING ALCOHOL AND DRUG HAZARD NEVER operate the engine while you are under the influence of alcohol or drugs NEVER operate the engine when you are feeling ill Failure to comply could result in death or serious injury 0000004en A WARNING BURN HAZARD Batteries contain sulfuric acid NEVER allow battery fluid to come in...

Page 74: ... to comply could result in death or serious injury 0000005en A WARNING SUDDEN MOVEMENT HAZARD Be sure the boat is in open water away from other boats docks and other obstructions before increasing rpm Failure to comply could result in death or serious injury 0000006enMarine A WARNING HIGH PRESSURE HAZARD Avoid skin contact with high pressure diesel fuel spray caused by a fuel system leak such as a...

Page 75: ... begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine 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 Failure to comply...

Page 76: ...you Failure to comply could result in death or serious injury 0000016enMarine A WARNING BURN HAZARD Keep your hands and other body parts away from hot engine surfaces such as the muffler exhaust pipe turbocharger if equipped and engine block during operation and shortly after you shut the engine down These surfaces are extremely hot while the engine is operating and could seriously burn you Failur...

Page 77: ...minor or moderate injury 0000003en CAUTION Only use diesel fuels recommended by Yanmar for the best engine performance to prevent engine damage and to comply with EPA warranty requirements Only use clean diesel fuel NEVER remove primary strainer from the fuel tank filler port If removed dirt and debris could get into the fuel system causing it to clog 0000004enMarine CAUTION NEVER attempt to adjus...

Page 78: ...ne Operate the engine normally 0000151en CAUTION Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear NEVER run the engine if the ambient temperature is above 40 C 104 F or below 16 C 5 F If the ambient temperature exceeds 40 C 104 F the engine may overheat and cause the engine oil to break down If the ambient temperature falls bel...

Page 79: ... dipstick and the surrounding area before you remove the cap NEVER mix different types of 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 CAUTION NEVER overfill the engine with engine oil ALWAYS keep the oil level between upper and lower lines on the oil cap ...

Page 80: ...proper engine oil pressure diesel fuel leaks engine oil leaks coolant leaks and for proper operation of the indicators and or gauges During the first 50 hours of operation operate your new engine under a substantial load at all times For best break in results operate the engine at various speeds Operating the engine in NEUTRAL must be avoided During the first 50 hours avoid operation below 2000 rp...

Page 81: ...nd or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en CAUTION Protect the air cleaner turbocharger if equipped and electric components from damage when you use steam or high pressure water to clean the engine 0000014en CAUTION Establish a periodic maintenance plan according to the engine application and make sure you perform the requir...

Page 82: ...rator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out 0000025en CAUTION When the engine is operated in dusty conditions clean the air cleaner element more frequently NEVER operate the engine with the air cleaner or element s removed This may al...

Page 83: ...ill shorten the life of the engine Yanmar Replacement Parts Yanmar recommends that you use genuine Yanmar parts when replacement parts are needed Genuine replacement parts help ensure long engine life Tools Required Before you start any periodic maintenance procedure make sure you have the tools you need to perform all of the required tasks Ask Your Authorized Yanmar Marine Dealer or Distributor F...

Page 84: ...liance with EPA Emission Standards This product is an EPA approved engine The following are the conditions that must be met in order to ensure that the emissions during operation meet the EPA standards Be sure to follow these The operating conditions should be as follows Ambient temperature 20 40 C 4 104 F Relative humidity 80 or lower Permissible value for intake negative pressure 3 9 kPa 400 mmA...

Page 85: ...n are covered in Periodic Maintenance Schedule on page 78 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 Tightening Fasteners Use the correct amount of torque when you tighten fasteners on the machine Applying excessive torq...

Page 86: ...ant Level on page 42 Check the low pressure indicator See Checking the Alarm Indicators on page 45 Check the fuel level See Filling the Fuel Tank on page 34 Checking the battery electrolyte level See Check the Battery Electrolyte Level Servicable Batteries Only on page 91 Clean the battery See Clean the Battery on page 110 Check for any leakage rectify as necessary See Check for Leakage of Fuel En...

Page 87: ...ting System Check the engine oil level Crankcase c Replace the engine oil Crankcase 1st time Replace the engine oil filter element 1st time Clean engine oil cooler z Cooling System Seawater outlet c During Operation Check coolant level c Check the seawater pump impeller c Replace the engine coolant Every year When long life coolant is used replace every two years See Engine Coolant Specifications ...

Page 88: ...r shaft alignment z 1st time z Check replace flexible engine mounts c Parts Interval Clean fuel injection nozzle 1500 hours Check fuel injection nozzle adjustment 3000 hours Check fuel injection pump adjustment Check turbocharger adjustment Check electronic engine management system EMS and its associated sensors and actuators c Check Replace z Contact your authorized Yanmar marine dealer or distri...

Page 89: ...n the engine oil after operation while the engine is still warm After Initial 50 Hours of Operation A WARNING BURN HAZARD If you must drain the engine oil while it is still hot stay clear of the hot engine oil to avoid being burned ALWAYS wear eye protection Failure to comply could result in death or serious injury 0000011en CAUTION Only use the engine oil specified Other engine oils may affect wa...

Page 90: ...ure 1 3 into the snap fastener in the lid 8 Make sure that all oil is drained from the filter housing 9 Replace the filter lid Figure 1 1 and tighten to 25 N m 18 ft lb Note If the deposits in the centrifugal cleaner are more than 20 mm 3 4 in thick replace the oil filter more often The same is true for cleaning the centrifugal oil cleaner and changing the oil See Clean the Centrifugal Engine Oil ...

Page 91: ...t on the rotor bowl counterclockwise three turns Figure 2 Figure 2 If the nut is jammed clamp the nut in a vise and turn the rotor three turns counterclockwise by hand or with a wrench Figure 3 IMPORTANT NEVER clamp the rotor in a vise NEVER strike the rotor bowl Doing so may cause damage resulting in imbalance Figure 3 CAUTION NEVER overfill the engine with engine oil ALWAYS keep the oil level be...

Page 92: ...plate Figure 4 5 Scrape off the deposits from the inside of the rotor bowl Figure 5 If there are no deposits the cleaner is not working properly If the deposits are thicker than 20 mm 3 4 in clean the oil cleaner more often Figure 5 6 Wash all of the parts in suitable parts cleaning solvent 7 Make sure the nozzles on the rotor are not blocked or damaged 8 Make sure the bearings are not damaged 9 I...

Page 93: ...15 N m 133 in lb Figure 9 1 Be careful not to damage the rotor shaft nut or bowl while tightening the lock nut Figure 9 Functional Inspection The rotor spins very fast and should continue to turn when the engine has stopped To check rotor rotation 1 Stop the engine after it is warm 2 Listen for a whirring sound from the rotor or check if the cleaner housing is vibrating The rotor normally continue...

Page 94: ...ust Propeller Shaft Alignment Refer to reverse gear manufacturer literature for alignment procedure A WARNING ENTANGLEMENT HAZARD Stop the engine before you begin to service it NEVER leave the key in the key switch when you are servicing the engine Someone may accidentally start the engine and not realize you are servicing it This could result in a serious injury If you must service the engine whi...

Page 95: ...th or serious injury 0000011en CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground...

Page 96: ...nd lock the clamps Figure 12 2 8 If the restriction indicator Figure 12 3 on the top of the filter is red remove the plastic cover and reset the restriction indicator button 9 Reinstall the drainage line Figure 12 CAUTION Only use the engine oil specified Other engine oils may affect warranty coverage cause internal engine components to seize or shorten engine life Prevent dirt and debris from con...

Page 97: ... FIRE AND EXPLOSION HAZARD Diesel fuel is flammable and explosive under certain conditions When you remove any fuel system component to perform maintenance such as changing the fuel filter place an approved container under the opening to catch the fuel NEVER use a shop rag to catch the fuel Vapors from the rag are flammable and explosive Wipe up any spills immediately Wear eye protection The fuel ...

Page 98: ...t when the fuel filter water separator drain cock is opened If this happens turn the air vent screw on the top of the fuel filter water separator 2 3 turns counterclockwise Be sure to tighten the air vent screw after the water has drained out 0000025en CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous ...

Page 99: ... fuel filter water separator bleed air from the fuel system See Bleeding the Fuel System on page 36 Check the Battery Electrolyte Level Servicable Batteries Only 3 2 1 A WARNING BURN HAZARD 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 clothing when servicing the battery If...

Page 100: ...e 15 Note The maximum fill level is approximately 10 15 mm 3 8 9 16 in above the plates Note Battery fluid tends to evaporate in high temperatures especially in summer In such conditions inspect the battery earlier than specified CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engin...

Page 101: ... Intake Exhaust Valve Clearance Proper adjustment is necessary to maintain the correct timing for opening and closing the valves Improper adjustment will cause the engine to run noisily resulting in poor engine performance and engine damage See your authorized Yanmar marine dealer or distributor to adjust the intake exhaust valve clearance Check and Adjust the Unit Injector Rocker Arms Proper adju...

Page 102: ...han every 500 hours if the restriction indicator is red 1 Loosen clamps 2 Remove the filter element 3 Carefully blow the filter element clean from the inside with dry compressed air or install new filter element in housing Note There is a risk of damaging the filter when it is cleaned The filter can only be cleaned a maximum of four times A cleaned filter does not filter as well as a new filter 4 ...

Page 103: ...qualified technician See your authorized Yanmar marine dealer or distributor Clean the Charge Air Cooler CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materia...

Page 104: ...ld 6 Remove the charge air cooler assembly from the intake manifold IMPORTANT Under no circumstances should caustic soda be used to clean the components 7 Clean the element using paraffin based engine detergent only 8 Clean and degrease the sealing surfaces on the upper and lower intake manifold housing 9 Install charge air cooler s using a new gasket Tighten bolts to 20 N m 177 in lb 10 Install u...

Page 105: ...ur authorized Yanmar marine dealer or distributor Drain Flush and Refill the Engine Coolant Cooling performance drops when coolant is contaminated with rust and scale The coolant must be replaced periodically because its properties deteriorate over time A DANGER SCALD HAZARD NEVER remove the coolant filler cap if the engine is hot Steam and hot engine coolant will escape and seriously burn you All...

Page 106: ...fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal...

Page 107: ...p if the engine is hot Steam and hot engine coolant will escape and seriously burn you Allow the engine to cool sufficiently before attempting to remove the filler cap Securely tighten the filler cap after checking the coolant level Steam can escape during engine operation if the cap is loose Failure to comply will result in death or serious injury 0000002enMarine A WARNING BURN HAZARD Wait until ...

Page 108: ...en A CAUTION COOLANT HAZARD Wear eye protection and rubber gloves when you handle Long Life engine coolant If contact with the eyes or skin should occur flush eyes and wash immediately with clean water Failure to comply may result in minor or moderate injury 0000005enMarine CAUTION Only use the engine coolant specified Other engine coolants may affect warranty coverage cause an internal buildup of...

Page 109: ...4 25 26 Figure 20 1 Screw 2 Nameplate 3 Filler Cap 4 Heat Exchanger Housing 5 O Ring 6 Return Pipe to Coolant Pump 7 Bolt 8 Gasket 9 Plug 10 Gasket 11 Outlet from Engine 12 Bolt 13 Seal 14 Bolt 15 Seal 16 Anode 3 used 17 Front Cover 18 O Ring 19 Drain Plug 20 Gasket 21 Flange Nut 22 Bolt 23 Rear Cover 24 Gasket 25 Cooler Core 26 O Ring ...

Page 110: ...the components 10 Use paraffin based engine detergent to clean the element 11 Any internal deposits in the pipes can be removed mechanically using a round rod 12 Lubricate and install new a O ring Figure 20 26 inside the housing and install the cooler core 13 Install the front and rear covers using new O rings and gaskets 14 Install the heat exchanger assembly on the engine Tighten the flange nuts...

Page 111: ...e for about 20 30 minutes 7 Drain the water from the system 8 Reinstall the thermostats 9 Fill the system with new coolant See Engine Coolant on page 40 for refilling coolant 10 IRefill the system with hot water and run the engine for about 20 30 minutes 11 Drain the water from the system 12 Reinstall the thermostats 13 Fill the system with new coolant See Check Diesel Fuel Engine Oil and Engine C...

Page 112: ... cap 4 Check the impeller vanes for wear or damage IMPORTANT If the impeller must be changed frequently theseawaterstrainer mustbe replaced with a unit having better filtering capabilities Replace the Impeller 1 Remove the impeller using an impeller removal tool Figure 21 1 2 Install a new impeller and cap If the cap seal is hard or damaged replace it Figure 21 Note A spare impeller should be kept...

Page 113: ...See Adjust the Intake Exhaust Valve Clearance on page 93 Adjust Unit Injectors See your authorized Yanmar marine dealer or distributor Replace Flexible Engine Mounts See your authorized Yanmar marine dealer or distributor Perform the following maintenance every 2000 hours of operation Overhaul and Check Fuel Feed Pump Clean Engine Oil Cooler Clean Seawater and Engine Coolant System Replace Rubber ...

Page 114: ...he battery cables during operation Damage to the electric system will result 0000061en A WARNING SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the electrical system Check the electrical harnesses for cracks abrasions and damaged or corroded connectors ALWAYS keep the connectors and terminals clean Failure to comply could result in de...

Page 115: ... also used for lighting or other purposes the generating and charging capacities may be insufficient In such cases see your authorized Yanmar marine dealer or distributor Maintenance free batteries can be checked using a battery tester See your authorized Yanmar marine dealer or distributor Replace the Battery A WARNING Stop the engine and turn the starter switch key to the OFF position before che...

Page 116: ...ther governmental agencies for the proper disposal of hazardous materials such as engine oil diesel fuel and engine coolant Consult the local authorities or reclamation facility NEVER dispose of hazardous materials irresponsibly by dumping them into a sewer on the ground or into ground water or waterways Failure to follow these procedures may seriously harm the environment 0000013en A WARNING ENTA...

Page 117: ...l or the coolant pump assembly 6 A small amount of leakage from the overflow holes during the engine break in period is normal Seals and O rings are lubricated with soap or oil when installed This leakage normally stops after time Figure 22 CAUTION ALWAYS be environmentally responsible Follow the guidelines of the EPA or other governmental agencies for the proper disposal of hazardous materials su...

Page 118: ...d 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 clean water and obtain prompt medical treatment Failure to comply could result in death or serious injury 0000007en A WARNING SHOCK HAZARD Turn off the battery switch if equipped or disconnect the negative battery cable before servicing the elec...

Page 119: ...m corrosion and the exterior from rusting The engine can normally stand idle for up to six months If it remains unused for longer than this please contact your authorized Yanmar marine dealer or distributor Winter Storage Drain water from tank and fuel filters before and after extended storage To reduce the risk of condensation in the fuel tank during winter storage fill the tank with fuel and tre...

Page 120: ...LONG TERM STORAGE 114 6SY Operation Manual This Page Intentionally Left Blank ...

Page 121: ...Displacement 11 7 L 714 cu in Firing Order 1 5 3 6 2 4 Compression Ratio 16 1 Maximum rated output at crankshaft fuel 40 C 104 F 0 5 Output at rev speed 530 kW 720 hp at 2300 rpm Mean pressure 2 46 MPa 356 79 psi Idle Speed High idle 2400 rpm Low idle 600 rpm Rotation Direction Counterclockwise viewed from flywheel No of Valves Inlet 2 Exhaust 2 Turbocharger Single water cooled Electrical System 2...

Page 122: ...er gear driven Capacity 315 L min at 2300 rpm 83 gpm at 2300 engine rpm Gear Oil Cooler Restriction 150 mbar 0 03495 psi Lubrication System Totally enclosed forced lube system Oil cooler Closed coolant system Lube oil pressure Rated speed 300 600 kPa 44 87 psi Lube oil pressure Idling speed 150 kPa 22 psi Lube system capacity with filters 21 31 L 6 8 2 gal approximate Crankcase Ventilation Closed ...

Page 123: ...listed below provided the engine has been installed according to Yanmar installation requirements and there has been no abuse neglect or improper maintenance of your Yanmar marine engine Yanmar warrants that the engine is designed built and tested using genuine parts and equipped so as to conform to all applicable emission requirements of the U S Environmental Protection Agency and is free from de...

Page 124: ... any warranted parts will be performed at an authorized Yanmar dealer or distributor This limited emission control system warranty covers engine components that are a part of the emission control system of the engine as delivered by Yanmar to the original retail purchaser Such components may include the following 1 Fuel Injection System 2 Turbocharger System 3 Aftercooler 4 Electronic Engine Contr...

Page 125: ...ss You must present your marine engine to an authorized Yanmar dealer or distributor as soon as a problem exists Customer Assistance If you have any questions regarding your warranty rights and responsibilities or would like information on the nearest authorized Yanmar dealer or distributor you should contact Yanmar Marine USA Corporation for assistance Yanmar Marine USA Corporation 101 Internatio...

Page 126: ...President Yanmar Marine Int l ...

Page 127: ...President Yanmar Marine Int l ...

Page 128: ...EPA WARRANTY USA ONLY 120 6SY Operation Manual This Page Intentionally Left Blank ...

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