Yanmar 6SY Series Operation Manual
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Yanmar 6SY Series Operation Manual

Yanmar 6SY Series Operation Manual

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6SY
series
OPERATION MANUAL
P/N: 0ASYM-G00101
MARINE
ENGINE

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Summary of Contents for Yanmar 6SY Series

  • Page 1 series OPERATION MANUAL P/N: 0ASYM-G00101 MARINE ENGINE...
  • Page 2 / or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Yanmar and registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries.
  • Page 3 BSO II, SAV, EPA II, IMO and RCD. be considered a permanent part of the engine and remain with it. To help you enjoy your Yanmar 6SY engine for many years to come, please follow these • Constant efforts are made to improve the...

  • 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

    ..........General Information ......... Before You Operate ......... During Operation and Maintenance ..... Safety Decals ............Product Overview ............9 Yanmar 6SY Features and Applications ...... Component Identification ........Nameplate ............Engine Nameplate (Typical) ......Function of Major Components ........
  • Page 6 Keep a Log of Engine Hours and Daily Checks ..Yanmar Replacement Parts ......Tools Required ..........Tightening Fasteners ........Ask Your Authorized Yanmar Marine Dealer or Distributor For Help ........Required EPA Maintenance USA Only ....EPA Requirements USA Only ......EPA Requirements ..........
  • Page 7 Prepare Engine for Long-Term Storage ...... Specifications ............61 Principal Engine Specifications ........ EPA Warranty USA Only ..........63 Yanmar Co., Ltd. Limited Emission Control System Warranty - USA Only ..........Your Warranty Rights and Obligations: ....Warranty Period: ..........
  • Page 8 TABLE OF CONTENTS This Page Intentionally Left Blank viii 6SY Operation Manual...

  • Page 9: Safety

    SAFETY Yanmar considers safety of great DANGER importance and recommends that anyone Indicates a hazardous situation which, if that comes into close contact with its not avoided, will result in death or products, such as those who install, serious injury.

  • Page 10: Safety Precautions

    • Safety signs and decals are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar marine dealer or distributor for additional training. 6SY Operation Manual...
  • Page 11 SAFETY Sever Hazard WARNING Rotating parts can cause The safety messages that follow have severe injury or death. NEVER WARNING level hazards. wear jewelry, unbuttoned cuffs, ties or loose fitting Explosion Hazard clothing and ALWAYS tie long Avoid serious personal injury hair back when working near moving / or equipment damage.
  • Page 12 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 repair the damage. Avoid skin contact with high pressure hydraulic fluid spray caused by a system leak.
  • Page 13 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...
  • Page 14 (s). This water could cause seizure of the non-running engine(s). See your authorized Yanmar marine dealer or distributor for a complete explanation of this condition. If you have an installation with two or three...

  • Page 15: Safety Decals

    SAFETY SAFETY DECALS CAUTION DANGE R DANGER CAUTION CAUTION ! When connecting the seawater pipes make sure they are securely attached. 0004481 Figure 1 6SY Operation Manual...
  • Page 16 SAFETY This Page Intentionally Left Blank 6SY Operation Manual...

  • Page 17: Product Overview

    As new and engineering skills. See Yanmar's local boats are used, owners add additional subsidiary in your region or your authorized equipment and completely fill the fuel and Yanmar marine dealer or distributor.

  • Page 18: 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. (16) (15) (14) (26) (13) (11) (12) (10) (17) (18) (19) (25) (23) (27) (21) (24) (20) (22) 0004473 Figure 1...
  • Page 19 PRODUCT OVERVIEW 1 – Air Filter 15 – Seawater Inlet 2 – Coolant Filler Cap 16 – Seawater Pump 3 – Coolant Recovery Tank 17 – Charge Air Cooler 4 – Engine Oil Filler Cap 18 – Closed Crankcase Ventilation Filter 5 –...

  • Page 20: Nameplate

    PRODUCT OVERVIEW NAMEPLATE Figure 2 shows the location of regulatory information on Yanmar 6SY marine engines. Engine Nameplate (Typical) 6SY Engines MODEL CONT. RATING kW MAX OUTPUT kW ENGINE N O . Y ANMAR DIESEL ENGINE 0003496 Figure 2 6SY Operation Manual...

  • Page 21: Function Of Major Components

    PRODUCT OVERVIEW FUNCTION OF MAJOR COMPONENTS Name of part Function Fuel Filter Removes dirt and water from the fuel. Drain the filter periodically. The filter element should be replaced periodically. See Draining or Replacing the Fuel Filter Element and Fuel Filter / Water Separator on page 40. Fuel Feed Pump Pumps fuel from the tank to the fuel injection system.

  • Page 22: 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 which provide each cylinder with the right amount of fuel at the right time in all operating situations.

  • Page 23: Rotation Speeds

    PRODUCT OVERVIEW Rotation Speeds • If the temperature is high, 98˚ to 103˚C, (208˚ to 217˚F) for one second, the S6 Check instruments at regular intervals. control will send a CAN message which activates a warning. Rotation Speed • If the temperature exceeds 103˚C 0 - 500 rpm Prohibited engine speed, (217˚F), a warning is activated.
  • Page 24 PRODUCT OVERVIEW This Page Intentionally Left Blank 6SY Operation Manual...

  • Page 25: Before You Operate

    BEFORE YOU OPERATE DIESEL FUEL This section of the Operation Manual describes the diesel fuel, engine oil, and engine coolant specifications and how to Diesel Fuel Specifications replenish them. It also describes the daily Diesel fuel should comply with the following engine checkout.

  • Page 26: Filling The Fuel Tank

    5 – Fuel Tank Some fuel additives may cause poor engine performance. See your authorized 6 – Fuel Tank Drain Cock Yanmar marine dealer or distributor for 7 – Approximately 50 mm (1.96 in.) more information. 8 – Fuel Shutoff Valve •...

  • Page 27: Bleeding The Fuel System

    BEFORE YOU OPERATE Remove the fuel cap from the fuel tank. WARNING! ALWAYS wear safety WARNING! Wipe up all spills glasses when bleeding the fuel immediately. Keep sparks, open system. Open the bleeder valve and flames or any other form of ignition operate the hand pump (match, cigarette, static electric (Figure 2, (2)) until fuel flows without...

  • Page 28: Engine Oil

    Select the oil viscosity based on the ambient temperature where the engine is being 25° operated. See the SAE Service Grade Viscosity Chart. Yanmar does not recommend the use of engine oil “additives.” 25° Additional Technical Engine Oil Requirements:...

  • Page 29: Checking The Engine Oil

    BEFORE YOU OPERATE Checking the Engine Oil Adding Engine Oil Remove the oil fill port cap and fill with engine oil. Fill with oil to the upper limit (Figure 6, (2)) on the dipstick (Figure 6, (1)). Insert the dipstick fully to check the level.

  • Page 30: Engine Coolant

    BEFORE YOU OPERATE ENGINE COOLANT Following the manufacturer’s recommendations, use a proper LLC which will not have any adverse effects on the Engine Coolant Specifications materials (cast iron, aluminum, copper, etc.) Use a Long Life Coolant (LLC) that meets or of the engine’s fresh water cooling system.

  • Page 31: Daily Checks

    NOTICE: Only use the Before you head out for the day, make sure engine coolant specified. Other engine the Yanmar engine is in good operating coolants may affect warranty coverage, condition. Make sure you check the cause an internal buildup of rust and scale following items.

  • Page 32: Check For Fuel, Engine Oil And Engine Coolant Leaks

    Level on page 22 to check these levels. fuel leak with your hands. ALWAYS use a piece of wood or cardboard. Have your Checking and Refilling Marine authorized Yanmar marine dealer or Gear Oil distributor repair the damage. Refer to the operation manual for the marine gear.

  • Page 33: Cleaning The Battery

    ALWAYS and charging capacities may be insufficient. keep the connectors and terminals In such cases, see your authorized Yanmar clean. marine dealer or distributor. Checking the Battery Electrolyte Maintenance-free batteries can be checked Level using a battery tester.
  • Page 34 BEFORE YOU OPERATE This Page Intentionally Left Blank 6SY Operation Manual...

  • Page 35: Engine Operation

    ENGINE OPERATION This section of the Operation Manual WARNING describes the procedures for starting the Fire and Explosion Hazard engine, checking engine performance during operation and shutting the engine Avoid serious personal injury. down. NEVER jump start the engine. Sparks caused by shorting the battery to the starter terminals may cause a fire or explosion.
  • Page 36 ENGINE OPERATION WARNING CAUTION Sever Hazard Avoid serious personal injury or equipment Rotating parts can cause damage. ALWAYS turn severe injury or death. NEVER off the battery switch (if operate the engine without the equipped) or disconnect guards in place. the negative battery cable before servicing the equipment.

  • Page 37: Starting The Engine

    Starting at Low Temperatures • Contact your authorized Yanmar marine Comply with local environmental engine dealer or distributor if the engine requirements. Use engine heaters to avoid will be operated outside of this standard starting problems and white smoke.

  • Page 38: Shutting Down The Engine

    SHUTTING DOWN THE CHECKING THE ENGINE ENGINE AFTER OPERATION NOTICE: For maximum engine life, Yanmar • Check that the key switch is in the OFF recommends that when shutting the engine position and battery master switch (if down, you allow the engine to run, without equipped) is OFF.

  • Page 39: Periodic Maintenance

    PERIODIC MAINTENANCE SAFETY PRECAUTIONS Welding Hazard Make welding repairs safely. WARNING • ALWAYS turn off the battery switch (if equipped) or disconnect the negative Crush Hazard battery cable and the leads to the If you need to transport an alternator when welding on the engine for repair have a equipment.
  • Page 40 Any alterations to the equipment. this engine may void its warranty. Be sure to use Yanmar genuine replacement parts. Avoid personal injury or equipment damage. ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors.

  • Page 41: Precautions

    Yanmar Replacement Parts Performing Periodic Maintenance Yanmar recommends that you use genuine Yanmar parts when replacement parts are Perform periodic maintenance procedures needed. Genuine replacement parts help in an open, level area free from traffic. If ensure long engine life.

  • Page 42: Required Epa Maintenance Usa Only

    PERIODIC MAINTENANCE EPA REQUIREMENTS Required EPA Maintenance USA Only To maintain optimum engine performance The EPA emission regulation is applicable and compliance with the Environmental only in USA. Protection Agency (EPA) Regulation Conditions to Ensure Engines, it is essential that you follow the Compliance with EPA Emission Periodic Maintenance Schedule on page Standards...

  • Page 43: Inspection And Maintenance

    See the standard values during the warranty your authorized Yanmar marine dealer period. The warranty period is determined or distributor for assistance when by the age of the engine or the number of checking items marked with a ●.

  • Page 44: Engines With Low Operating Hours

    PERIODIC MAINTENANCE Engines with Low Operating Hours Run the engine until it reaches operating temperature and then perform the following maintenance procedures: • Check the engine oil level. See Checking the Engine Oil on page 21. • Check the coolant level. See Checking the Coolant Level on page 22.
  • Page 45 PERIODIC MAINTENANCE ○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor Periodic Maintenance Interval Every Every Every Every Every 50 hours 1000 2000 or one hours or hours or hours or hours or System...
  • Page 46 PERIODIC MAINTENANCE ○: Check or Clean ◊: Replace ●: Contact your authorized Yanmar marine dealer or distributor Periodic Maintenance Interval Every Every Every Every Every 50 hours 1000 2000 or one hours or hours or hours or hours or System...

  • Page 47: Inspection And Maintenance For Epa Emission-Related Parts

    Check fuel injection pump adjustment Check turbocharger adjustment (if equipped) Check electronic engine control unit (ECU) and its associated sensors and actuators Note: The inspection and maintenance items shown above to be performed at your Yanmar dealer or distributor. 6SY Operation Manual...

  • Page 48: Maintenance Procedures

    PERIODIC MAINTENANCE MAINTENANCE Clean the outside of the filter and PROCEDURES remove it by turning it counterclockwise. NOTICE: Put an approved container under the opening After Initial 50 Hours of when removing any fuel system Operation component to perform maintenance (such as changing the fuel filter).
  • Page 49 PERIODIC MAINTENANCE Loosen the drain plug (Figure 2, (3)) at It is easiest and most effective to drain the the bottom of the fuel filter / water engine oil after operation while the engine is separator and drain off any water or dirt. still warm.
  • Page 50 PERIODIC MAINTENANCE Fill with new engine oil. See Adding Lift out the rotor and turn the nut on the Engine Oil on page 21. NOTICE: Only rotor bowl counterclockwise three turns use the engine oil specified. Other (Figure 4). engine oils may affect warranty coverage, cause internal engine components to seize, or shorten engine life.
  • Page 51 PERIODIC MAINTENANCE Remove the strainer located on the rotor (Figure 6). If the strainer is stuck, use a screwdriver to carefully pry the bottom edge until it comes loose from the bottom plate. 0002377 0002377 Figure 5 Grasp the rotor bowl and tap on the 0004385 Figure 6 rotor nut with your hand or a plastic...
  • Page 52 Make sure the shaft is not loose. If the cleaning solvent. CAUTION! Avoid shaft is loose, see your authorized personal injury. Always wear Yanmar marine dealer or distributor. personal protective equipment Install the rotor. Turn the rotor by hand when using solvents or chemicals.
  • Page 53 If the belt deflection is not to specification, see your authorized Stop the engine after it is warm. Yanmar dealer or distributor for belt Listen for a whirring sound from the replacement. NOTICE: Do not get any rotor or check if the cleaner housing is oil on the belt(s).

  • Page 54: Every 50 Hours Of Operation

    PERIODIC MAINTENANCE If the level is lower than the minimum fill Every 50 Hours of Operation level (Figure 13, (1)), fill with distilled After you complete the initial 50 hour water (Figure 13, (2)) (available in the maintenance procedures, perform the grocery store) up to the upper limit following procedures every 50 hours or (Figure 13, (3)) of the battery.

  • Page 55: Every 250 Hours Of Operation

    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. 6SY Operation Manual...
  • Page 56 PERIODIC MAINTENANCE At the specified interval or when the volume of seawater discharged is reduced, inspect the seawater pump: Close the sea valve (seacock) if the marine water pump is under water. Drain the seawater circuit. WARNING! Wait until the engine cools before draining seawater from the cooling system.
  • Page 57 PERIODIC MAINTENANCE Checking or Replacing the Anodes ( 2 ) ( 3 ) ( 1 ) ( 4 ) 0004395 Figure 16 Drain the seawater cooling circuit and check the anodes (Figure 16). Scrape off all loose material on the anodes.
  • Page 58 PERIODIC MAINTENANCE This Page Intentionally Left Blank 6SY Operation Manual...
  • Page 59 PERIODIC MAINTENANCE Cleaning the Coolant System (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) 0004399 Figure 17 6SY Operation Manual...
  • Page 60 PERIODIC MAINTENANCE 1 – Screw 14 – Bolt 2 – Nameplate 15 – Seal 3 – Filler Cap 16 – Anode (3 used) 4 – Heat Exchanger Housing 17 – Front Cover 5 – O-Ring 18 – O-Ring 6 – Return Pipe to Coolant Pump 19 –...
  • Page 61 Cleaning or Replacing the Air Intake Filter Element If possible, run the engine until it has reached operating temperature and NOTICE: ALWAYS use genuine Yanmar then drain the coolant system. See replacement parts (super-fine mesh filter). Draining, Flushing and Refilling the Using anything except genuine Yanmar Engine Coolant on page 55.
  • Page 62 0004396 Figure 18 Cleaning the Exhaust / Water Mixing Elbow 0004471 Figure 19 See your authorized Yanmar marine dealer or distributor. 1 – Air Intake Manifold, Lower 2 – Gasket Cleaning the Turbocharger 3 – Charge Air Cooler Element Contamination of the turbocharger causes 4 –...
  • Page 63 Disconnect inlet and outlet water lines Engine Mounts from charge air cooler fittings. Seal the fittings with caps or plugs to prevent See your authorized Yanmar marine dealer coolant spillage. or distributor. Remove the upper intake manifold Draining, Flushing and Refilling the housing.

  • Page 64: Every 500 Hours Of Operation

    PERIODIC MAINTENANCE Drain the coolant: Every 500 Hours of Operation • from the two drain taps on the lower right side of the block Perform the following maintenance every (Figure 20, (2)) 500 hours of operation or every 2 years, whichever comes first.

  • Page 65: Every 1000 Hours Of Operation

    • Adjusting the Intake / Exhaust Valve Clearance • Replacing the Flexible Engine Mounts Adjusting the Unit Injectors / Rocker Arms See your authorized Yanmar marine dealer or distributor. Cleaning and Checking the Seawater Passages See your authorized Yanmar marine dealer or distributor.

  • Page 66: Every 2000 Hours Of Operation

    • Cleaning the Seawater and Engine Coolant System • Checking the Wiring Connectors Overhauling and Checking the Fuel Feed Pump See your authorized Yanmar marine dealer or distributor. Replacing the Rubber Fuel Hoses See your authorized Yanmar marine dealer or distributor.

  • Page 67: Long-Term Storage

    Wipe off any dust or oil from the outside than this, please contact your authorized of engine. Yanmar marine dealer or distributor. Drain water from fuel filters. Drain fuel tank completely or fill the tank to prevent condensation. To reduce the...
  • Page 68 LONG-TERM STORAGE This Page Intentionally Left Blank 6SY Operation Manual...

  • Page 69: Specifications

    SPECIFICATIONS PRINCIPAL ENGINE SPECIFICATIONS Engine Model 6SY-STP2 / 6SY655 Number of Cylinders In-line 6 Type Water-cooled, turbocharged Combustion System Direct injection Aspiration Turbocharged with intercooler Bore x Stroke 127 mm x 154 mm (5.0 in. x 6.1 in.) Displacement 11.7 L (714 cu in.) Firing Order 1-5-3-6-2-4 Compression Ratio...
  • Page 70 SPECIFICATIONS Engine Model 6SY-STP2 / 6SY655 Thermostats Coolant thermostat type and opening temperature Dual - 75˚C (167˚F) Charge air cooler type and opening temperature Single - 50˚C (122˚F) Seawater Pump Rubber impeller, gear driven Capacity 315 L / min at 2300 rpm (83 gpm at 2300 engine rpm) Gear Oil Cooler Restriction 150 mbar (0.03495 psi)

  • Page 71: Epa Warranty Usa Only

    ONLY YANMAR CO., LTD. LIMITED Where a warrantable emissions condition EMISSION CONTROL exists, Yanmar will repair your engine at no charge to you for diagnosis, parts, and labor. SYSTEM WARRANTY - USA Warranty service or repair will be provided ONLY at authorized Yanmar marine dealers or distributors.

  • Page 72: 6Sy Operation Manual

    You must present your marine engine to an authorized Failures other than those arising from Yanmar dealer or distributor as soon as a defects in material and / or workmanship are problem exists. not covered by this limited emissions warranty.
  • Page 73 6SY Operation Manual...
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