Yanmar 6LT Series Operation Manual
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Yanmar 6LT Series Operation Manual

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TABLE OF
CONTENTS
6LT Series Operation Manual
Introduction ............................................................................................. 1
Record of Ownership........................................................................... 2
Safety........................................................................................................ 3
Safety Precautions .............................................................................. 4
Product Overview.................................................................................... 9
New Engine Break-in........................................................................... 9
Component Identification................................................................... 10
Nameplates ....................................................................................... 14
Vessel Control System (VC20).......................................................... 16
Control the Backup Panel.................................................................. 22
Engine Management from Relay Box................................................ 23
Before You Operate............................................................................... 25
Diesel Fuel Specifications ................................................................. 26
Refilling.............................................................................................. 28
Engine Operation .................................................................................. 29
Preliminary Checks ........................................................................... 30
For Proper Use of the Engine............................................................ 30
6LT Series Operation Manual
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  • Page 1: Table Of Contents

    Introduction ..................... 1 Record of Ownership................2 Safety......................3 Safety Precautions ................4 Product Overview..................9 Yanmar 6LT Common Rail Series Features and Applications .... 9 New Engine Break-in................9 Component Identification..............10 Nameplates ..................14 Vessel Control System (VC20)............16 Control the Backup Panel..............
  • Page 2 Check Tension and Condition of Auxiliary Belt ......... 55 Change Engine Coolant ..............56 Change Air Filter ................57 Change Oil Vapor Filters ..............57 Periodic and Extraordinary Maintenance Operations......58 Change the Auxiliary Belt ..............59 6LT Series Operation Manual...
  • Page 3 Engine Start-up after a Long Period of Inactivity....... 62 Directions for the First Start-up and Start-up after a Long Period of Inactivity .................... 62 Engine Malfunctions ................63 Specifications ..................65 EPA Warranty USA Only............... 67 EU Declaration of Conformity .............. 70 6LT Series Operation Manual...
  • Page 4 TABLE OF CONTENTS This Page Intentionally Left Blank 6LT Series Operation Manual...

  • Page 5: Introduction

    To help you enjoy your Yanmar 6LT series engine Please refer to the manual provided by the for many years to come, please follow these manufacturer of these components.

  • Page 6: Record Of Ownership

    INTRODUCTION RECORD OF OWNERSHIP Take a few moments to record the information you need when you consult Yanmar for service, parts or documentation. Engine Model: ______________________________________________________________________ Engine Serial No.: ___________________________________________________________________ Date Purchased: ____________________________________________________________________ Dealer: ____________________________________________________________________________ Dealer Phone: ______________________________________________________________________ To Register Your Yanmar Engine 1.

  • Page 7: Safety

    6LT Series Operation Manual SAFETY Yanmar considers safety of great importance and DANGER recommends that anyone that comes into close contact with its products, such as those who install, Indicates a hazardous situation which, if not operate, maintain or service Yanmar products, avoided, will result in death or serious injury.

  • Page 8: Safety Precautions

    Never use improper capacity of reminders for safe operating and maintenance fuses. techniques. Store any containers containing fuel or other Consult authorized Yanmar Marine dealer or flammable products in a well-ventilated area, distributor for additional training. away from any combustibles or source of ignition.
  • Page 9 Never block windows, vents or other means of ventilation if the engine is operating in an enclosed area. All internal combustion engines create carbon monoxide gas during operation and special precautions are required to avoid carbon monoxide poisoning. 6LT Series Operation Manual...
  • Page 10 Immediately throttle back to approximately If a Yanmar Marine Engine is installed at an angle 2/3 throttle or to a setting where the engine that exceeds the specifications stated in the performs normally.
  • Page 11 (on the tank, if present). Presence of parts at high temperature. Risk of fire: Engine oil filling cap. Presence of fuel. Risk of injury from moving parts: Engine oil level dipstick. Presence of fans, pulleys, belts or other. 6LT Series Operation Manual...
  • Page 12 SAFETY This Page Intentionally Left Blank 6LT Series Operation Manual...

  • Page 13: Product Overview

    Applying for any other purpose except recreational knowledge and engineering skills. See Yanmar’s and light duty commercial can lead to reduced local subsidiary in your region or your authorized vessel performance, lead to increased smoke Yanmar Marine dealer or distributor.

  • Page 14: Component Identification

    Right side view Air filter Sacrificial anodes Lifting eye Fuel filter Coolant Filler Cap High-pressure pump for common rail Engine coolant-seawater heat exchanger system 10 Starter motor Seawater pump inlet 11 Seawater Drain Air-seawater heat exchanger Figure 1 6LT Series Operation Manual...
  • Page 15 Left side view Oil filters Exhaust and seawater outlet Turbocharger Coolant expansion tank Oil sump Oil level dipstick 10 Oil drain plug Oil filler cap 11 Oil sump evacuation pump Lifting eye Electronic control unit Figure 2 6LT Series Operation Manual...
  • Page 16 Oil sump Oil filter Seawater pump inlet Thermostat body 10 Engine coolant-seawater heat exchanger Coolant inlet pipe going to engine water 11 Blow-by gas valve pump 12 Oil filler cap Oil evacuation pump Engine mounts Figure 3 6LT Series Operation Manual...
  • Page 17 PRODUCT OVERVIEW Rear view Air filter Turbine geometry actuator Coolant expansion tank Fuel Pipes Turbocharger Seawater pump inlet 10 Oil filler cap Engine mounts 11 Intake pipe Engine flywheel Oil sump Figure 4 6LT Series Operation Manual...

  • Page 18: Nameplates

    PRODUCT OVERVIEW NAMEPLATES IDENTIFICATION DATA The plates are fixed to the engine coolant tank. ENGINE NAMEPLATE LABEL ON EXPANSION TANK 6LT500 6LT580 6LT640 Figure 5 6LT Series Operation Manual...
  • Page 19 PRODUCT OVERVIEW EPA LABEL ON EXPANSION TANK 6LT500 6LT580 6LT640 Figure 6 6LT Series Operation Manual...

  • Page 20: Vessel Control System (Vc20)

    If this system is not utilized in specific accordance with the instructions in this manual or the system is modified in any way, Yanmar will not be responsible for any warranty failures in the operation of the system or the vessel utilizing the system. Yanmar has designed the Vessel Control System (VC20) in conjunction with the 6LT engine.
  • Page 21 If the system does not function normally, consult your authorized Yanmar Marine dealer or distributor and ask for diagnostics. 6LT Series Operation Manual...
  • Page 22 Switch to the monitor screen in the normal Display Indication indication. Send the screen in order with the   buttons. The monitor screen is fixed when there is no operation with the   buttons for 5 seconds. 6LT Series Operation Manual...
  • Page 23 Brightness 3. Set the minimum and maximum brightness as Utility Night mode required. Auto dimmer • The brightness is adjusted in 8 steps. Auto dimmer limit MAIN MENU Figure 13 OIL PRESSURE COOLANT TEMP Figure 15 6LT Series Operation Manual...
  • Page 24 Under normal circumstances, do not use the Emergency Stop Switch to stop the engine. The engine shuts down suddenly when the Emergency Stop Switch is pressed. After the engine has stopped, press the Emergency Stop Switch to release the emergency stop. 6LT Series Operation Manual...
  • Page 25  button and the Enter next digit is highlighted. • Press the [ENTER] button after highlighting it with the  button when all 5 digits are entered and the Figure 19 new ID becomes valid. 6LT Series Operation Manual...

  • Page 26: Control The Backup Panel

    • When controlling the throttle, always move it fully anti-clockwise first. Emergency stop switch • Be sure to lower the engine speed by turning the Emergency stop switch sub throttle volume fully to anti-clockwise before stopping the engine. Figure 20 6LT Series Operation Manual...

  • Page 27: Engine Management From Relay Box

    • Increasing and reducing the rotation speed. speed reached at each change will be maintained until the next change or until the • Self-diagnostics test (to be carried out only by engine is stopped. Technical Service Network personnel). 6LT Series Operation Manual...
  • Page 28 2. Move the switch (1) to the BRIDGE position to allow use of the controls on the instrument panels and exclude the use of the START-STOP button from the “Relay Box”. 6LT Series Operation Manual...

  • Page 29: Before You Operate

    6LT Series Operation Manual BEFORE YOU OPERATE INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual describes the Before performing any operations within this diesel fuel, engine oil and engine coolant section, review the Safety section on page 3. specifications and how to replenish them.

  • Page 30: Diesel Fuel Specifications

    JIS K2204 Grade No. 2 Japan Biodiesel Fuels Yanmar approves the use of biodiesel fuels that do not exceed a blend of 7% non-mineral oil based fuel with 93% standard diesel fuel. Such biodiesel fuels are known in the marketplace as B7 biodiesel fuels.
  • Page 31 Less than 30% is preferred. • PAH (polycyclic aromatic hydrocarbons) content should be below 10% by volume. • Do not use Biocide. • Lubricity: Wear mark of WS1.4 should be Max. 0.016 in. (400 μm) at HFRR test. 6LT Series Operation Manual...

  • Page 32: Refilling

    Oil sump at maximum level additive to facilitate removal of any residue before changing the fluid. If a concentrated product is *1: Engine coolant: Yanmar Long Life Coolant used, mix it 50% with water. recommended or organic base long life coolant •...

  • Page 33: Engine Operation

    6LT Series Operation Manual ENGINE OPERATION INTRODUCTION SAFETY PRECAUTIONS This section of the Operation Manual describes the Before performing any operations within this procedures for starting the engine, checking engine section, review the Safety section on page 3. performance during operation and shutting down the engine.

  • Page 34: Preliminary Checks

    - 2400 RPM (see page 9). • During navigation, check that: • The temperature of the engine coolant has not exceeded the alarm thresholds. • The oil pressure remains within the expected normal values. 6LT Series Operation Manual...
  • Page 35 WARNING Risk of injury The rotating elements are located below the protective covers. They must only be removed when the engine is not running. Failure to comply with these warnings can result in serious injury. 6LT Series Operation Manual...

  • Page 36: Vc20 Starting The Engine

    OFF. The Power switch must be ON at all times when the engine is running. ENGINE SPEED 4. Do not press the engine START/STOP switch OIL PRESSURE COOLANT TEMP except for stopping the engine. Figure 4 6LT Series Operation Manual...

  • Page 37: Warm Up Mode (Shift Disconnect)

    • Is the seacock open? • Is the inlet of the seacock on the hull bottom clogged? • Is the seawater suction hose broken, or does the hose suck in air due to a loose joint? 6LT Series Operation Manual...

  • Page 38: Throttle And Shift Control

    Forward (Reverse) to Reverse (Forward) Moving the handle quickly and switching from forward (reverse) to reverse (forward) will activate Figure 7 the gear shift delay (astern delay). The engine speed will decrease to idle speed for several seconds. 6LT Series Operation Manual...

  • Page 39: Cautions During Operation

    Depending on the hull structure, engine and hull resonance may suddenly become great at a certain engine speed range, causing heavy vibrations. Avoid operation in this speed range. If you hear any abnormal sounds, stop the engine and inspect. 6LT Series Operation Manual...

  • Page 40: Shutting Down The Engine (Stopping)

    (rpm)) for about 5 minutes. system when the ambient temperature is below 0 °C (32 °F). For maximum engine life, Yanmar recommends that when shutting the engine down, you allow the engine to idle, without load, for 5 minutes. This will allow the engine components that...

  • Page 41: Checking The Engine After Operation

    • If there is a risk of freezing, drain the seawater system. • At temperatures below 0 °C (32 °F), drain seawater system and connect the engine heater (if equipped). Check fluid levels See instructions in Before You Operate on page 25. 6LT Series Operation Manual...
  • Page 42 ENGINE OPERATION This Page Intentionally Left Blank 6LT Series Operation Manual...

  • Page 43: Inspection And Maintenance

    6LT Series Operation Manual INSPECTION AND MAINTENANCE INTRODUCTION WARNING This section of the Operation Manual describes the Welding Hazard procedures for proper care and maintenance of the • Always turn off the battery switch (if engine. equipped) or disconnect the negative battery cable and the leads to the alternator when welding on the equipment.

  • Page 44: Precautions

    Failure to perform periodic maintenance will engine’s life. Any alterations to this engine may shorten the life of the engine and may void the void its warranty. Be sure to use Yanmar genuine warranty. replacement parts. Yanmar Replacement Parts...
  • Page 45 44.1 ± 5 53.9 ± 5 Tightening Torque ft-lb 10.9 ± 1.5 16.6 ± 2.2 21.7 ± 3.7 32.6 ± 3.7 69.8 ± 3.7 When seal washer applied, torque is 34 ± 5 N·m (25.1 ± 3.7 ft-lb). 6LT Series Operation Manual...

  • Page 46: Epa Maintenance Requirements

    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. 6LT Series Operation Manual...

  • Page 47: Maintenance Schedule

    3) Engine coolant standard solution: organic base compliant with specifications ASTM D6210 Type 1-FF. If concentrated products are used, they must be mixed 50% with water. Original Yanmar products are recommended. 4) The anode must be replaced if the corrosion has affected more than 50% of the volume of zinc.
  • Page 48 3) Engine coolant standard solution: organic base compliant with specifications ASTM D6210 Type 1-FF. If concentrated products are used, they must be mixed 50% with water. Original Yanmar products are recommended. 4) The anode must be replaced if the corrosion has affected more than 50% of the volume of zinc.

  • Page 49: Maintenance Procedures

    Make sure that the dipstick is fully inserted and that the filler cap is tightened fully in the clockwise direction. CHECK THE OIL LEVEL IN THE MARINE GEAR Check the level of the oil in the Marine Gear following the instructions provided in the manual supplied by the Manufacturer. 6LT Series Operation Manual...

  • Page 50: Check The Coolant Level

    CHECK THE CONDITION OF THE EXHAUST DUCT(S) Visually check that the exhaust gas / exhaust system is not obstructed or damaged. Make sure that there is no risk of any dangerous fumes inside the hull. Contact the boatyard if necessary. 6LT Series Operation Manual...

  • Page 51: Draining The Water From The Fuel Pre-Filter

    (for example filters) in accordance with the law. The workshops of the Service Network are equipped for this purpose. Correct behavior will ensure that vehicle is used as environmentally friendly as possible. 6LT Series Operation Manual...

  • Page 52: Check The Electrolyte Level Of The Batteries - Clean Terminals

    • Check that the terminals and clamps are clean, well tightened and protected by battery terminal grease or petroleum jelly. Some batteries are equipped with a single cover for the inspection plugs. To access the elements, use a lever as indicated in the figure. 6LT Series Operation Manual...

  • Page 53: Clean The Air Filter

    When using compressed air, it is required to use suitable personal protections for hands, face and eyes.The requirements can be found in the ACCIDENT PREVENTION paragraph. Failure to comply with these prescriptions can result in the risk of serious injury. 6LT Series Operation Manual...

  • Page 54: Check The State Of Corrosion Of The Zinc Anodes

    • Reposition the filter in its seat following the indications provided for replacement. Drain impurities from fuel tank Carry out the draining/suction of water and condensation from the fuel tank following the instructions given in the manual supplied by the boat builder. 6LT Series Operation Manual...

  • Page 55: Change The Engine Oil

    • Place a container for collecting the spent oil under the circuit charge/ discharge tap (1). • Open the tap and move the button (A) on the panel to DISCHARGE until the sump is completely empty. 6LT Series Operation Manual...

  • Page 56: Change Engine Oil Filters

    Figure 8 NOTE: The following procedure is by way of example only. Only use original Yanmar filters. Only proceed once the engine is stationary and has been allowed to cool, and preferably after having drained the waste oil, in order to avoid the risk of burns.

  • Page 57: Change The Fuel Filter

    Failure to comply completely or partially with these system. requirements may result in the risk of serious damage to the engine and may even, on occasion, invalidate the warranty. 6LT Series Operation Manual...

  • Page 58: Change Fuel Pre-Filter

    9. Close the Air Bleed Valve. WARNING Risk of injury Dispose of consumable materials and the parts in contact with them (for example filters) in accordance with the law. The workshops of the Service Network are equipped for this purpose. 6LT Series Operation Manual...

  • Page 59: Check Tension And Condition Of Auxiliary Belt

    • Check the efficiency of the tensioner (3) using the tool (2) on the tensioner as indicated in the figure. • Reposition the belt cover in its seat and tighten the fasteners. 6LT Series Operation Manual...

  • Page 60: Change Engine Coolant

    • Leave the engine idling and carefully loosen the screw positioned on the coolant tank beside the cap. • Once a sufficient amount of time has passed, tighten the screw to the specified torque and stop the engine. • Check the coolant level again and top up if necessary. 6LT Series Operation Manual...

  • Page 61: Change Air Filter

    • Unscrew the screws (2) and remove the cover (1). Remove the centrifugal filter (3) below and replace it. • Close the cover (1) and tighten the screws (2). ATTENTION: The blow-by body must be fit in perfect alignment with the camshaft to prevent damaging the gasket. 6LT Series Operation Manual...

  • Page 62: Periodic And Extraordinary Maintenance Operations

    It is recommended that these operations are carried out by qualified personnel belonging to the Yanmar Service Network. Consult an authorized Yanmar Marine dealer or distributor. Failure to comply...

  • Page 63: Change The Auxiliary Belt

    CHANGE THE AUXILIARY BELT Figure 15 Only proceed with the operation when the engine is not in operation and is at a low temperature. This is to avoid the risk of burns: • Remove the belt cover. (1) 6LT Series Operation Manual...
  • Page 64 Failure to comply with these prescriptions can occasion, invalidate the warranty. result in the risk of serious injury. 6LT Series Operation Manual...

  • Page 65: Long Term Storage

    6LT Series Operation Manual LONG TERM STORAGE The engine should be started and run for 30 minutes every 3 months. If this is not possible the following steps are required. PREPARING THE ENGINE FOR LONG TERM STORAGE 3 months to 24 months...

  • Page 66: Engine Start-Up After Along Period Of Inactivity

    WITHOUT OIL” from the engine and instrument cap. panel. • Once a sufficient amount of time has passed, tighten the screw to the specified torque and stop the engine. • Check the coolant level again and top up if necessary. 6LT Series Operation Manual...

  • Page 67: Engine Malfunctions

    6LT Series Operation Manual ENGINE MALFUNCTIONS ENGINE MALFUNCTION ATTENTION: The engine’s electronic control unit may adopt the safety strategies at any point during The electronic unit which oversees management navigation when conditions arise which could and control of the entire engine operation is able to compromise the integrity of the engine.
  • Page 68 ENGINE MALFUNCTIONS This Page Intentionally Left Blank 6LT Series Operation Manual...

  • Page 69: Specifications

    6LT Series Operation Manual SPECIFICATIONS PRINCIPLE ENGINE SPECIFICATIONS 6LT640 Specification 6LT500 6LT580 For light duty commercial use For recreational use Type Vertical water cooled 4-cycle diesel engine Combustion System Direct injection (Common rail system) Air Charging Turbocharged with air cooler...
  • Page 70 SPECIFICATIONS This Page Intentionally Left Blank 6LT Series Operation Manual...

  • Page 71: Epa Warranty Usa Only

    6LT Series Operation Manual EPA WARRANTY USA ONLY 6LT Series Operation Manual...
  • Page 72 • Exhaust Manifold Where a warrantable emissions condition exists, • Turbocharger System Yanmar will repair your engine at no charge to you • After cooler for diagnosis, parts, and labor. Warranty service or repair will be provided at authorized Yanmar Marine •...
  • Page 73 EPA WARRANTY USA ONLY Owner’s Responsibility: As the Yanmar Marine engine owner, you are responsible for the performance of the required maintenance listed in your Operation Manual. Yanmar recommends that you retain all documentation, including receipts, covering maintenance on your marine engine, but Yanmar...

  • Page 74: Eu Declaration Of Conformity

    EU DECLARATION OF CONFORMITY EU DECLARATION OF CONFORMITY 6LT Series Operation Manual...
  • Page 75 EU DECLARATION OF CONFORMITY 6LT Series Operation Manual...
  • Page 76 EU DECLARATION OF CONFORMITY 6LT Series Operation Manual...

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6lt5806lt500

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