Yanmar 6SY Series Bedienungsanleitung

6SY

series

OPERATION MANUAL

6SY Operation Manual

P/N 0A6301-G0000

MARINE

ENGINES

ii 6SY Operation Manual

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.

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.

6SY Operation Manual iii

INTRODUCTION

6SY Operation Manual

Welcome to the world of Yanmar Marine!

Yanmar Marine offers engines, drive

systems and accessories for all types of

boats, from runabouts to sailboats, and

from cruisers to mega yachts. In marine

leisure boating, the worldwide reputation of

Yanmar Marine is second to none. We

design our engines to respect nature. This

means quieter engines, with minimal

vibrations, cleaner than ever. All of our

engines designed after 1996 meet most of

the present and future emission

regulations, such as BSO II, SAV, EPA II,

IMO and RCD.

To help you enjoy your Yanmar 6SY engine

for many years to come, please follow

these recommendations:

• Read and understand this Operation

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.

• Make sure this manual is transferred to

subsequent owners. This manual should

be considered a permanent part of the

engine and remain with it.

• Constant efforts are made to improve the

quality and performance of Yanmar

products, so some details included in

this Operation Manual may differ slightly

from your engine. If you have any

questions about these differences,

please contact your authorized Yanmar

marine dealer or distributor.

• The specifications and components

(instrument panel, fuel tank, etc.)

described in this manual may differ from

ones installed on your vessel. Please

refer to the manual provided by the

manufacturer of these components.

INTRODUCTION

iv 6SY Operation Manual

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:___________________________________________________________

6SY Operation Manual v

TABLE OF

CONTENTS

6SY Operation Manual

Page

Introduction..................................................................... iii

Table of Contents ............................................................ v

Safety............................................................................... 1

Safety Precautions ..................................................... 2

Before You Operate............................................. 2

During Operation and Maintenance..................... 3

Product 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

TABLE OF CONTENTS

vi 6SY Operation Manual

Engine Oil ................................................................. 37

Engine Oil Specifications ................................... 38

Service Categories................................ 38

Definitions ............................................. 38

Additional Technical Engine Oil

Requirements:....................................... 38

Engine Oil Viscosity ........................................... 38

Maximum Angles of Inclination During

Operation .............................................. 39

Checking Engine Oil........................................... 39

Adding Engine Oil .............................................. 40

Selection of Marine Gear Oil .............................. 40

Engine Coolant ......................................................... 40

Engine Coolant Specifications ........................... 41

Coolant (Closed Cooling System) ...................... 41

Checking the Coolant Level ............................... 42

Daily Checks............................................................. 44

Visual Checks .................................................... 44

Check Diesel Fuel, Engine 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 Precautions ................................................... 59

Before You Operate ........................................... 59

During Operation and Maintenance ................... 60

Precautions............................................................... 74

The Importance of Periodic Maintenance .......... 74

Performing Periodic Maintenance ...................... 75

The Importance of Daily Checks ........................ 75

Keep a Log of Engine Hours and Daily

Checks ............................................................... 75

Yanmar Replacement Parts ............................... 75

Tools Required................................................... 75

TABLE OF CONTENTS

6SY Operation Manual vii

Ask Your Authorized Yanmar

Marine Dealer or Distributor

For Help............................................................. 75

Required EPA Maintenance

USA Only........................................................... 76

EPA Requirements

USA Only........................................................... 76

EPA Requirements................................................... 76

Conditions to Ensure Compliance with EPA

Emission Standards........................................... 76

Inspection and Maintenance.............................. 77

Tightening Fasteners......................................... 77

Periodic Maintenance Schedule ........................ 78

Engines with Low Operating Hours ................... 78

Inspection and Maintenance of EPA

Emission-Related Parts............................... 80

Periodic Maintenance Procedures..................... 81

After Initial 50 Hours of Operation............... 81

Replace Engine Oil and Engine 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 Battery Electrolyte Level (

Servicable Batteries Only) .................... 91

Every 250 Hours of Operation..................... 93

Adjust the Intake / Exhaust Valve

Clearance ............................................. 93

Check and Adjust the Unit Injector

Rocker Arms ......................................... 93

Drain the Fuel Tank .............................. 93

Check or Replace the Anodes (

Engines with Heat Exchangers)............ 94

Replace the Air Intake Filter ................. 94

Clean the Turbocharger........................ 95

Clean the Charge Air Cooler................. 95

TABLE OF CONTENTS

viii 6SY Operation Manual

Check the Wiring Connectors ............... 97

Tighten All Major Nuts and Bolts........... 97

Check or Replace Flexible Engine

Mounts .................................................. 97

Drain, Flush, and Refill the Engine

Coolant.................................................. 97

Clean the Coolant System .................... 99

Every 500 Hours of Operation ................... 104

Check or Replace the Seawater

Pump 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 the Battery ................................ 110

Long-Term Storage..................................................... 113

Specifications.............................................................. 115

Principal Engine Specifications ........................ 115

6SY Operation Manual 1

SAFETY

6SY Operation Manual

Yanmar considers safety of great

importance and recommends that

anyone that comes into close contact

with its products, such as those who

install, operate, maintain or service

Yanmar products exercise care,

common sense and comply with the

safety information in this manual and

on the machine’s safety labels. Keep

the labels from becoming dirty or torn

and replace them if they are lost or

damaged. Also, if you need to replace

a part that has a label attached to it,

make sure you order the new part and

label at the same time.

AThis 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.

ADANGER

Danger (the word “DANGER” is

in white letters with a red

rectangle behind it) – indicates

an imminently hazardous

situation which, if not avoided,

will result in death or serious

injury. Danger is limited to the

most extreme situations.

0000001en

AWARNING

Warning (the word “WARNING”

is in black letters with an orange

rectangle behind it) – indicates a

potentially hazardous situation

which, if not avoided, could

result in death or serious injury.

0000001en

SAFETY

26SY Operation Manual

SAFETY PRECAUTIONS

Before You Operate

ACAUTION

Caution (the word “CAUTION” is

in black letters with a yellow

rectangle behind it) – indicates a

potentially hazardous situation

which, if not avoided, may result

in minor or moderate injury.

0000001en

CAUTION

Caution without the safety alert

symbol indicates a potentially

hazardous situation that 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 labels are

additional reminders for safe

operating and maintenance

techniques.

• See your authorized Yanmar

marine dealer or distributor for

additional training.

0000002enMarine

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