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Yanmar 6SY Series Operation Manual

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6SY
series
OPERATION MANUAL
6SY Operation Manual
P/N 0A6301-G0000
MARINE
ENGINES

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Summary of Contents for Yanmar 6SY Series

  • Page 1 series OPERATION MANUAL 6SY Operation Manual P/N 0A6301-G0000 MARINE ENGINES...
  • Page 2 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.

  • Page 3: Introduction

    IMO and RCD. • The specifications and components (instrument panel, fuel tank, etc.) To help you enjoy your Yanmar 6SY engine described in this manual may differ from for many years to come, please follow ones installed on your vessel. Please...

  • Page 4: Record Of Ownership

    INTRODUCTION 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...

  • Page 5: Table Of Contents

    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 .....
  • Page 6 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 6SY Operation Manual...
  • Page 7 TABLE OF CONTENTS 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......
  • Page 8 TABLE OF CONTENTS 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)..........

  • Page 9: Safety

    SAFETY 6SY Operation Manual Yanmar considers safety of great DANGER importance and recommends that Danger (the word “DANGER” is anyone that comes into close contact in white letters with a red with its products, such as those who rectangle behind it) – indicates...

  • Page 10: Safety Precautions

    0000001enMarine 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 6SY Operation Manual...

  • Page 11: During Operation And Maintenance

    SAFETY During Operation and DANGER Maintenance DANGER SCALD HAZARD! • NEVER remove the coolant filler cap if the engine is hot. EXPLOSION HAZARD! Steam and hot engine coolant • Keep the area around the will escape and seriously burn battery well-ventilated. While you.
  • Page 12 SAFETY DANGER 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. • When you remove any fuel • NEVER use diesel fuel as a system component to perform cleaning agent.
  • Page 13 SAFETY DANGER DANGER FIRE AND EXPLOSION FIRE AND EXPLOSION HAZARD! HAZARD! • Diesel fuel is flammable and • Only use the key switch to start explosive under certain the engine. conditions. • NEVER jump start the engine. • Only fill the fuel tank with Sparks caused by shorting the diesel fuel.
  • Page 14 SAFETY DANGER DANGER FIRE AND EXPLOSION EXPLOSION HAZARD! HAZARD! • NEVER check the remaining • Diesel fuel is flammable and battery charge by shorting out explosive under certain the terminals. This will result in conditions. a spark and may cause an •...
  • Page 15 SAFETY DANGER DANGER FIRE AND EXPLOSION HAZARD! CRUSH HAZARD! • Diesel fuel is extremely • ALWAYS use the engine lifting flammable and explosive under eyes when lifting the marine certain conditions. engine. The lifting eyes are • When you prime the fuel engineered to lift the weight of system, operate the fuel the marine engine only.
  • Page 16 SAFETY WARNING 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.
  • Page 17 SAFETY WARNING WARNING ALCOHOL AND DRUG HAZARD! EXPOSURE HAZARD! • NEVER operate the engine • Wear personal protective while you are under the equipment such as gloves, influence of alcohol or drugs. work shoes, eye and hearing • NEVER operate the engine protection as required by the when you are feeling ill.
  • Page 18 ALWAYS use • Batteries contain sulfuric acid. a piece of wood or cardboard. NEVER allow battery fluid to Have your authorized Yanmar come in contact with clothing, marine dealer or distributor skin or eyes. Severe burns repair the damage.
  • Page 19 SAFETY WARNING WARNING SHOCK HAZARD! WELDING SHOCK • Turn off the battery switch (if HAZARD! equipped) or disconnect the • Turn off the battery switch (if negative battery cable before equipped) or disconnect the servicing the electrical system. negative battery cable and the •...
  • Page 20 SAFETY WARNING 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 being burned. •...
  • Page 21 SAFETY WARNING CAUTION BURN HAZARD! • Keep your hands, and other COOLANT HAZARD! body parts, away from hot engine surfaces such as the • Wear eye protection and muffler, exhaust pipe, rubber gloves when you turbocharger (if equipped) and handle Long Life engine engine block during operation coolant.
  • Page 22 SAFETY 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.
  • Page 23 • See your authorized Yanmar shorten engine life. marine dealer or distributor if • Prevent dirt and debris from you need to operate the engine contaminating engine oil.
  • Page 24 SAFETY CAUTION CAUTION Make sure the engine is installed • NEVER overfill the engine with on a level surface. If a Yanmar engine oil. Marine Engine is installed at an • ALWAYS keep the oil level angle that exceeds the...
  • Page 25 SAFETY CAUTION 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 • ALWAYS be environmentally operating the engine. responsible. 0000028enMarine • Follow the guidelines of the...
  • Page 26 SAFETY CAUTION CAUTION If the fuel filter / water separator NEVER turn off the battery is positioned higher than the fuel switch (if equipped) or short the level in the fuel tank, water may battery cables during operation. not drip out when the fuel Damage to the electric system filter / water separator drain cock will result.

  • Page 27: Product Overview

    The engine is knowledge and engineering skills. See turbocharged and equipped with a charge Yanmar's local subsidiary in your region or air cooler containing a liquid coolant your authorized Yanmar marine dealer or system.

  • Page 28: Component Identification

    PRODUCT OVERVIEW COMPONENT IDENTIFICATION Figure 1 illustrates a typical version of a 6SY engine. Your engine may have different equipment from that illustrated. (18) (19) (17) (25) (24) (16) (20) (23) (15) (21) (14) (13) (11) (10) (12) (22) Figure 1 1.

  • Page 29: Nameplate

    PRODUCT OVERVIEW NAMEPLATE The following figure (Figure 2) shows the location of regulatory and safety labels on Yanmar 6SY marine engines. Engine Nameplate (Typical) 6SY Engines MODEL CONT. RATING kW MAX OUTPUT kW ENGINE NO. YANMAR DIESEL ENGINE 0003496 Figure 2...

  • Page 30: Function Of Major Components

    PRODUCT OVERVIEW FUNCTION OF MAJOR COMPONENTS Name of part Function Removes dirt and water from the fuel. Drain the filter periodically. The filter Fuel Filter element should be replaced periodically. See Drain or Replace the Fuel Filter Element and Fuel Filter / Water Separator on page 89. Fuel Feed Pump Pumps fuel from the tank to the fuel injection system.

  • Page 31: Engine Management System (Ems S6)

    PRODUCT OVERVIEW ENGINE MANAGEMENT Positions of Sensors for EMS with S6 SYSTEM (EMS S6) This engine has an Electronic Management System (EMS) with unit injectors (PDE) which provide each cylinder with the right amount of fuel at the right time in all operating situations. The EMS system consists of a control unit (S6) and sensors for speed, charge air temperature and pressure, coolant...

  • Page 32: Rotation Speeds

    PRODUCT OVERVIEW Rotation Speeds Coolant Temperature Check instruments at regular intervals. Normal coolant temperature when the engine is running is 70° - 90°C Rotation Speed (158° - 194°F). 0 - 500 rpm Prohibited engine speed, The EMS / S6 control system has the passed through when stopping following alarm levels: and starting.

  • Page 33: Oil Pressure

    PRODUCT OVERVIEW Oil Pressure The EMS has the following alarm levels: • At a speed of less than 1000 rpm and an oil pressure of less than 1.0 bar (15 psi) • At a speed of more than 1000 rpm and an oil pressure of less than 2.3 bar (33 psi) for longer than five seconds The following functions are available if...
  • Page 34 PRODUCT OVERVIEW This Page Intentionally Left Blank 6SY Operation Manual...

  • Page 35: Before You Operate

    • 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 6SY Operation Manual...
  • Page 36 BEFORE YOU OPERATE DANGER DANGER FIRE AND EXPLOSION HAZARD! SCALD HAZARD! • Diesel fuel is flammable and • NEVER remove the coolant explosive under certain filler cap if the engine is hot. conditions. Steam and hot engine coolant • Only fill the fuel tank with will escape and seriously burn diesel fuel.
  • Page 37 BEFORE YOU OPERATE DANGER DANGER FIRE AND EXPLOSION FIRE AND EXPLOSION 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 •...
  • Page 38 ALWAYS use primed. The fuel filter has an a piece of wood or cardboard. internal air bleed port. Have your authorized Yanmar • Failure to comply will result in marine dealer or distributor death or serious injury.
  • Page 39 BEFORE YOU OPERATE WARNING WARNING BURN HAZARD! BURN HAZARD! • If you must drain the engine oil • Wait until the engine cools while it is still hot, stay clear of before you drain the engine the hot engine oil to avoid coolant.
  • Page 40 BEFORE YOU OPERATE CAUTION CAUTION • Only use diesel fuels • Only use the engine coolant recommended by Yanmar for specified. Other engine the best engine performance, coolants may affect warranty to prevent engine damage and coverage, cause an internal...

  • Page 41: Diesel Fuel

    / 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. 6SY Operation Manual...

  • Page 42: Diesel Fuel Lines

    BEFORE YOU OPERATE Diesel Fuel Lines Filling the Fuel Tank Install the lines between the fuel tank and the fuel injection pump. DANGER Be sure to install a drain cock (Figure 1, (6)) at the bottom of the fuel tank to remove water and contaminants. Install an fuel filter / water separator FIRE AND EXPLOSION (Figure 1, (3)) and a fuel filter between the...
  • Page 43 • Failure to comply will result in CAUTION death or serious injury. • Only use diesel fuels 0000014en recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA warranty requirements. • Only use clean diesel fuel.

  • Page 44: Bleeding The Fuel System

    BEFORE YOU OPERATE To fill the fuel tank: The fuel system needs to be bled under the following conditions: 1. Clean the area around the fuel cap. 2. Remove the fuel cap from the fuel tank. • Before starting the engine for the first 3.

  • Page 45: Engine Oil

    BEFORE YOU OPERATE If the engine fails to start after bleeding: • 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 Figure 2 1.

  • Page 46: Engine Oil Specifications

    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 reduced to 2.0.

  • Page 47: Maximum Angles Of Inclination During Operation

    BEFORE YOU OPERATE Maximum Angles of Inclination Checking Engine Oil During Operation 1. Make sure engine is level. Maximum permissible angles during 2. Remove dipstick (Figure 5, (1)) and operation vary, depending on the type of oil wipe with clean cloth. sump (Figure 4).

  • Page 48: Adding Engine Oil

    BEFORE YOU OPERATE ENGINE COOLANT Adding Engine Oil CAUTION DANGER • NEVER overfill the engine with engine oil. • ALWAYS keep the oil level between upper and lower lines on the oil cap / dipstick. SCALD HAZARD! 0000015en • NEVER remove the coolant filler cap if the engine is hot.

  • Page 49: Engine Coolant Specifications

    BEFORE YOU OPERATE Engine Coolant Specifications CAUTION Use a Long Life Coolant (LLC) that meets or exceeds the following guidelines and specifications: • ASTM D6210, D4985 (US) • JIS K-2234 (Japan) • SAE J814C, J1941, J1034 or J2036 COOLANT HAZARD! (International) •...

  • Page 50: Checking The Coolant Level

    BEFORE YOU OPERATE Following the manufacturer’s Checking the Coolant Level recommendations. Use a proper LLC which will not have any adverse effects on the materials (cast iron, aluminum, copper, DANGER etc.) of the engine’s fresh water cooling system. See Engine Coolant Specifications.
  • Page 51 BEFORE YOU OPERATE CAUTION CAUTION COOLANT HAZARD! COOLANT HAZARD! • Wear eye protection and When adding large amounts of rubber gloves when you coolant, NEVER pour cold handle Long Life engine coolant into a hot engine. coolant. If contact with the The cylinder block and cylinder eyes or skin should occur, head could crack.

  • Page 52: Daily Checks

    DAILY CHECKS CAUTION Before you head out for the day, make sure It is important to perform daily the Yanmar engine is in good operating checks as listed in the Operation condition. Make sure you check the Manual. following items.

  • Page 53: Check Diesel Fuel, Engine Oil, And Engine Coolant Levels

    BEFORE YOU OPERATE Preparing Fuel, Oil and Coolant CAUTION in Reserve If any problem is noted during Prepare sufficient fuel for the day’s the visual check, the necessary operation. Always store engine oil and corrective action should be coolant in reserve (for at least one refill) on taken before you operate the board, to be ready for emergencies.
  • Page 54 BEFORE YOU OPERATE This Page Intentionally Left Blank 6SY Operation Manual...

  • Page 55: Engine Operation

    • 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 6SY Operation Manual...

  • Page 56: Engine Operation

    ENGINE OPERATION DANGER DANGER EXPLOSION HAZARD! SCALD HAZARD! • Keep the area around the • NEVER remove the coolant battery well-ventilated. While filler cap if the engine is hot. the engine is running or the Steam and hot engine coolant battery is charging, hydrogen will escape and seriously burn gas is produced which can be...
  • Page 57 ENGINE OPERATION DANGER 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. • Only fill the fuel tank with • NEVER remove the fuel cap diesel fuel.
  • Page 58 ENGINE OPERATION DANGER DANGER FIRE AND EXPLOSION FIRE AND EXPLOSION 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 •...
  • Page 59 ENGINE OPERATION WARNING 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.
  • Page 60 ENGINE OPERATION WARNING WARNING ALCOHOL AND DRUG EXPOSURE HAZARD! HAZARD! • Wear personal protective • NEVER operate the engine equipment such as gloves, while you are under the work shoes, eye and hearing influence of alcohol or drugs. protection as required by the •...
  • Page 61 WARNING • NEVER check for a fuel leak 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.
  • Page 62 0000003enMarine in death or serious injury. 0000016enMarine CAUTION • Only use diesel fuels CAUTION 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...
  • Page 63 ENGINE OPERATION CAUTION CAUTION • Only use the engine oil • Only use the engine coolant specified. Other engine oils specified. Other engine may affect warranty coverage, coolants may affect warranty cause internal engine coverage, cause an internal components to seize, or buildup of rust and scale shorten engine life.
  • Page 64 0000152en 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...

  • Page 65: Starting Engine

    CAUTION 3. Put transmission in neutral. For maximum engine life, 4. Turn the battery master switch (if Yanmar recommends that when equipped) ON. shutting the engine down, you allow the engine to run, without 5. Press the ENG ON switch (if equipped) load, for five minutes.

  • Page 66: Checking The Engine After Operation

    ENGINE OPERATION CHECKING THE ENGINE AFTER OPERATION • Check that the key switch is in the OFF position and battery master switch (if equipped) is OFF. • Fill the fuel tank. Make sure that the fill cap and the area around the fill opening are clean to avoid contamination of the fuel.

  • Page 67: Periodic Maintenance

    • 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 6SY Operation Manual...

  • Page 68: During Operation And Maintenance

    PERIODIC MAINTENANCE During Operation and DANGER Maintenance DANGER SCALD HAZARD! • NEVER remove the coolant filler cap if the engine is hot. EXPLOSION HAZARD! Steam and hot engine coolant • Keep the area around the will escape and seriously burn battery well-ventilated.
  • Page 69 PERIODIC MAINTENANCE DANGER 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. • When you remove any fuel • NEVER use diesel fuel as a system component to perform cleaning agent.
  • Page 70 PERIODIC MAINTENANCE DANGER DANGER FIRE AND EXPLOSION FIRE AND EXPLOSION HAZARD! HAZARD! • Diesel fuel is flammable and • Only use the key switch to start explosive under certain the engine. conditions. • NEVER jump start the engine. • Only fill the fuel tank with Sparks caused by shorting the diesel fuel.
  • Page 71 PERIODIC MAINTENANCE DANGER DANGER FIRE AND EXPLOSION EXPLOSION HAZARD! HAZARD! • NEVER check the remaining • Diesel fuel is flammable and battery charge by shorting out explosive under certain the terminals. This will result in conditions. a spark and may cause an •...
  • Page 72 PERIODIC MAINTENANCE DANGER WARNING FIRE AND EXPLOSION SEVER HAZARD! HAZARD! • Keep hands and other body • Diesel fuel is flammable and parts away from explosive under certain moving / rotating parts such as conditions. the flywheel or PTO shaft. •...
  • Page 73 PERIODIC MAINTENANCE WARNING WARNING EXHAUST HAZARD! ALCOHOL AND DRUG • NEVER operate the engine in HAZARD! an enclosed area such as a • NEVER operate the engine garage, tunnel, underground while you are under the room, manhole or ship’s hold influence of alcohol or drugs.
  • Page 74 • NEVER check for a fuel leak 0000005en with your hands. ALWAYS use a piece of wood or cardboard. Have your authorized Yanmar marine dealer or distributor repair the damage. • Failure to comply could result in death or serious injury.
  • Page 75 PERIODIC MAINTENANCE WARNING 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.
  • Page 76 PERIODIC MAINTENANCE WARNING WARNING BURN HAZARD! BURN HAZARD! • Keep your hands, and other • If you must drain the engine oil body parts, away from hot while it is still hot, stay clear of engine surfaces such as the the hot engine oil to avoid muffler, exhaust pipe, being burned.
  • Page 77 PERIODIC MAINTENANCE CAUTION CAUTION • Only use diesel fuels recommended by Yanmar for the best engine performance, to prevent engine damage and to comply with EPA warranty requirements. COOLANT HAZARD! • Only use clean diesel fuel. • Wear eye protection and •...
  • Page 78 OFF position. be operated in either • Be sure to re-open the seacock temperature extreme. and restart the engine. Operate • See your authorized Yanmar the engine normally. marine dealer or distributor if 0000151en you need to operate the engine at high altitudes.
  • Page 79 For maximum engine life, remove the cap. Yanmar recommends that when shutting the engine down, you • NEVER mix different types of allow the engine to run, without engine coolants. This may load, for five minutes.
  • Page 80 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...
  • Page 81 PERIODIC MAINTENANCE CAUTION CAUTION If seawater is left inside of the Protect the air cleaner, engine, it may freeze and turbocharger (if equipped) and damage parts of the cooling electric components from system when the ambient damage when you use steam or temperature is below 0°C (32°F).

  • Page 82: Precautions

    PERIODIC MAINTENANCE CAUTION CAUTION If the fuel filter / water separator NEVER turn off the battery is positioned higher than the fuel switch (if equipped) or short the level in the fuel tank, water may battery cables during operation. not drip out when the fuel Damage to the electric system filter / water separator drain cock will result.

  • Page 83: Performing Periodic Maintenance

    Yanmar Replacement Parts operation. Accumulation of this gas within an enclosure Yanmar recommends that you use genuine could cause illness or even Yanmar parts when replacement parts are death. needed. Genuine replacement parts help ensure long engine life.

  • Page 84: Required Epa Maintenance Usa Only

    PERIODIC MAINTENANCE Required EPA Maintenance • Ambient temperature: -20° - 40°C (-4° - 104°F) USA Only • Relative humidity: 80% or lower To maintain optimum engine performance and compliance with the Environmental • Permissible value for intake negative Protection Agency (EPA) Regulations pressure: 3.9 kPa (400 mmAq) or lower Engines, it is essential that you follow the •...

  • Page 85: Inspection And Maintenance

    PERIODIC MAINTENANCE Inspection and Maintenance Tightening Fasteners Use the correct amount of torque when See Inspection and Maintenance of EPA you tighten fasteners on the machine. Emission-Related Parts on page 80 for the Applying excessive torque may damage EPA emission-related parts. Inspection the fastener or component and not enough and maintenance procedures not shown in torque may cause a leak or component...

  • Page 86: Periodic Maintenance Schedule

    Fuel, Engine Oil and Engine Coolant on shorten the engine’s life and may page 108. affect the warranty coverage on your engine. See your authorized Yanmar marine dealer or distributor for assistance when checking items marked with a 0000024en6LY3 6SY Operation Manual...
  • Page 87 PERIODIC MAINTENANCE : Check : Replace : Contact your authorized Yanmar marine dealer or distributor Periodic Maintenance Interval Every Every 250 Every 500 Every 1000 Every 50 hrs. or hrs. or one hrs. or 2 hrs. or 4 2000 hrs.

  • Page 88: Inspection And Maintenance Of Epa Emission-Related Parts

    PERIODIC MAINTENANCE : Check : Replace : Contact your authorized Yanmar marine dealer or distributor Periodic Maintenance Interval Every Every 250 Every 500 Every 1000 Every 50 hrs. or hrs. or one hrs. or 2 hrs. or 4 2000 hrs.

  • Page 89: Periodic Maintenance Procedures

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE WARNING PROCEDURES After Initial 50 Hours of Operation BURN HAZARD! • If you must drain the engine oil Perform the following maintenance after while it is still hot, stay clear of the initial 50 hours of operation. the hot engine oil to avoid •...
  • Page 90 PERIODIC MAINTENANCE 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. Figure 1 Consult the local authorities or reclamation facility.

  • Page 91: Clean The Centrifugal Engine Oil Cleaner

    PERIODIC MAINTENANCE 2. Lift out the rotor and turn the nut on the CAUTION rotor bowl counterclockwise three turns • NEVER overfill the engine with (Figure 2). engine oil. • ALWAYS keep the oil level between upper and lower lines on the oil cap / dipstick.
  • Page 92 PERIODIC MAINTENANCE 3. Grasp the rotor bowl and tap on the rotor nut with your hand or a plastic hammer to loosen the rotor from the bowl. 4. Remove the strainer located on the rotor (Figure 4). If the strainer is stuck, use a screwdriver to carefully pry the bottom edge until it comes loose from the bottom plate.

  • Page 93: Functional Inspection

    2. Make sure the shaft is not loose. If the shaft is loose, see your authorized 1. Stop the engine after it is warm. Yanmar marine dealer or distributor. 2. Listen for a whirring sound from the 3. Install the rotor. Turn the rotor by hand...

  • Page 94: Check And Adjust The Alternator Belt

    2. If the belt deflection is not to and not realize you are specification, see your authorized servicing it. This could result Yanmar dealer or distributor for belt in a serious injury. replacement. • If you must service the engine...

  • Page 95: Replace The Closed Crankcase Ventilation Filter Element

    PERIODIC MAINTENANCE Replace the Closed Crankcase CAUTION Ventilation Filter Element WARNING • ALWAYS be environmentally responsible. • Follow the guidelines of the BURN HAZARD! EPA or other governmental • If you must drain the engine oil agencies for the proper while it is still hot, stay clear of disposal of hazardous the hot engine oil to avoid...
  • Page 96 PERIODIC MAINTENANCE 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 contaminating engine oil. Carefully clean the oil Figure 11 cap / dipstick and the surrounding area before you...

  • Page 97: Every 50 Hours Of Operation

    PERIODIC MAINTENANCE Drain or Replace the Fuel Filter Every 50 Hours of Element and Fuel Filter / Water Separator Operation After you complete the initial 50 hour DANGER maintenance procedures, perform the following procedures every 50 hours thereafter. • Drain Fuel Filter and Fuel Filter / Water FIRE AND EXPLOSION Separator HAZARD!
  • Page 98 PERIODIC MAINTENANCE Drain or Replace the Fuel Filter Element CAUTION If the fuel filter / water separator is positioned higher than the fuel level in the fuel tank, water may not drip out when the fuel filter / water separator drain cock is opened.

  • Page 99: Check The Battery Electrolyte Level (Servicable Batteries Only)

    PERIODIC MAINTENANCE Drain or Replace the Fuel Filter / Water Check the Battery Electrolyte Separator Level (Servicable Batteries 1. Make sure the fuel tank cock Only) (Figure 14, (1)) is closed. WARNING BURN HAZARD! • Batteries contain sulfuric acid. NEVER allow battery fluid to come in contact with clothing, skin or eyes.
  • Page 100 PERIODIC MAINTENANCE 3. If the level is lower than the minimum fill CAUTION level (Figure 15, (1)), fill with distilled water (Figure 15, (2)) (available in the grocery store) up to the upper limit (Figure 15, (3)) of the battery. •...

  • Page 101: Every 250 Hours Of Operation

    250 hours of operation. resulting in poor engine performance and engine damage. See your authorized • Check Unit Injector Spray Pattern Yanmar marine dealer or distributor to • Adjust Intake / Exhaust Valve Clearance adjust the intake / exhaust valve clearance. (1st Time) Check and Adjust the Unit •...

  • Page 102: Check Or Replace The Anodes (Engines With Heat Exchangers)

    Exchangers) Drain the seawater cooling circuit and check the anodes (Figure 16). CAUTION Note: Only two anodes are shown. ALWAYS use genuine Yanmar replacement parts (super-fine mesh filter). Using anything except genuine Yanmar parts can cause engine damage, uneven engine performance and shorten engine life.

  • Page 103: Clean The Turbocharger

    If a significant drop in engine output is procedures may seriously noted (10% or more), clean the harm the environment. turbocharger. 0000013en This should be done only by a trained and qualified technician. See your authorized Yanmar marine dealer or distributor. 6SY Operation Manual...
  • Page 104 PERIODIC MAINTENANCE 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, Figure 18 flush eyes and wash 1. Upper Intake Housing immediately with clean water. 2.

  • Page 105: Check The Wiring Connectors

    • Securely tighten the filler cap after checking the coolant Check the Wiring Connectors level. Steam can escape during See your authorized Yanmar marine dealer engine operation if the cap is or distributor. loose. • Failure to comply will result in Tighten All Major Nuts and death or serious injury.
  • Page 106 PERIODIC MAINTENANCE CAUTION CAUTION • Only use the engine coolant specified. Other engine coolants may affect warranty coverage, cause an internal buildup of rust and scale • ALWAYS be environmentally and / or shorten engine life. responsible. • Prevent dirt and debris from •...

  • Page 107: Clean The Coolant System

    PERIODIC MAINTENANCE Clean the Coolant System DANGER SCALD HAZARD! • NEVER remove the coolant filler cap if the engine is hot. Steam and hot engine coolant Figure 19 will escape and seriously burn you. Allow the engine to cool 3. Close the drain taps (Figure 19, (1), sufficiently before attempting (2)) and replace the heat exchanger to remove the filler cap.
  • Page 108 PERIODIC MAINTENANCE CAUTION CAUTION • ALWAYS be environmentally responsible. COOLANT HAZARD! • Follow the guidelines of the • Wear eye protection and EPA or other governmental rubber gloves when you agencies for the proper handle Long Life engine disposal of hazardous coolant.
  • Page 109 PERIODIC MAINTENANCE (10) (11) (21) (22) (14) (20) (12) (15) (19) (23) (12) (13) (18) (12) (14) (18) (14) (15) (17) (15) (12) (16) (24) (13) (25) (26) Figure 20 1. Screw 10. Gasket 20. Gasket 11. Outlet from Engine 21.
  • Page 110 PERIODIC MAINTENANCE Internal Cleaning - Heat Exchanger 14.Install the heat exchanger assembly on the engine. Tighten the flange nuts to 1. Drain the coolant from the engine and 50 N·m from the heat exchanger. See Drain, (37 ft-lb). Flush, and Refill the Engine Coolant on page 97.
  • Page 111 PERIODIC MAINTENANCE 4. Run the engine until warm (about CAUTION 20 - 30 minutes). 5. Drain the coolant system. See Drain, Flush, and Refill the Engine Coolant on page 97. 6. Fill the system again using clean, hot water and run the engine for about •...

  • Page 112: Every 500 Hours Of Operation

    PERIODIC MAINTENANCE At the specified interval or when the Every 500 Hours of volume of seawater discharged is reduced, Operation inspect the seawater pump: 1. Close the sea valve (seacock) if the marine water pump is under water. Perform the following maintenance every 500 hours of operation.

  • Page 113: Every 1000 Hours Of Operation

    Perform the following maintenance every Overhaul and Check Fuel Feed 1000 hours of operation. Pump See your authorized Yanmar marine dealer • Check the Unit Injector Spray Pattern or distributor. • Adjust Intake / Exhaust Valve Clearance Clean Engine Oil Cooler •...

  • Page 114: Check The Battery Charge

    PERIODIC MAINTENANCE Check the Battery Charge WARNING WARNING SHOCK HAZARD! BURN HAZARD! • Turn off the battery switch (if • Batteries contain sulfuric acid. equipped) or disconnect the NEVER allow battery fluid to negative battery cable before come in contact with clothing, servicing the electrical system.

  • Page 115: Replace The Battery

    In such cases, see 0000118en 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. 6SY Operation Manual...

  • Page 116: Check For Leakage Of Fuel, Engine Oil And Engine Coolant

    PERIODIC MAINTENANCE Install the Battery CAUTION 1. Install the new battery. 2. Connect the positive cable (+) to the battery (cable connected to starter motor). 3. Connect the negative cable (-) last to • ALWAYS be environmentally the battery (ground cable). responsible.
  • Page 117 PERIODIC MAINTENANCE 5. Check that there are no leaks from the CAUTION coolant pump. If a leak occurs, replace the pump seal or the coolant pump assembly. 6. A small amount of leakage from the overflow holes during the engine break-in period is normal.

  • Page 118: Clean The Battery

    PERIODIC MAINTENANCE Clean the Battery WARNING WARNING SHOCK HAZARD! BURN HAZARD! • Turn off the battery switch (if equipped) or disconnect the • Batteries contain sulfuric acid. negative battery cable before NEVER allow battery fluid to servicing the electrical system. come in contact with clothing, skin or eyes.

  • Page 119: Long-Term Storage

    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.
  • Page 120 LONG-TERM STORAGE This Page Intentionally Left Blank 6SY Operation Manual...

  • Page 121: Specifications

    SPECIFICATIONS 6SY Operation Manual PRINCIPAL ENGINE SPECIFICATIONS Engine Model 6SY-STP Number of Cylinders In-line 6 Type Water-cooled, turbocharged Combustion System Direct injection Aspiration Turbocharged intercooler Bore x Stroke 127 mm x 154 mm (5.0 in. x 6.063 in.) Displacement 11.7 L (714 cu in.) Firing Order 1-5-3-6-2-4 Compression Ratio...
  • Page 122 SPECIFICATIONS Engine Model 6SY-STP Injection Timing Variable (EMS controlled) Maximum Allowable Exhaust Backpressure 1000 mmAq (39.37 in.Aq) Closed cooling system with seawater heat Cooling System exchanger Coolant capacity with expansion tank 40 L (10.5 gal) Thermostats Engine type and opening temperature Dual - 75°C (167°F) Charge air cooler type and opening temperature Single - 50°C (122°F)
  • Page 123 TO THE ENGINES CERTIFIED TO Where a warrantable emissions condition UNITED STATES EPA 40 CFR 94 AND exists, Yanmar will repair your engine at no SOLD BY YANMAR THAT ARE charge to you for diagnosis, parts, and INSTALLED IN VESSELS FLAGGED OR labor.

  • Page 124: Epa Warranty Usa Only

    Repair or replacement of any warranted replacement of emission control systems parts will be performed at an authorized are Yanmar parts. The owner may elect to Yanmar dealer or distributor. This limited have maintenance, replacement or repair emission control system warranty covers...

  • Page 125: Customer Assistance

    You are responsible for initiating the warranty process. 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...
  • Page 126 President, Yanmar Marine Int’l...
  • Page 127 President, Yanmar Marine Int’l...
  • Page 128 EPA WARRANTY USA ONLY This Page Intentionally Left Blank 6SY Operation Manual...

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