Related Manuals for Yanmar 6LT640
Summary of Contents for Yanmar 6LT640
- Page 1 OPERATION MANUAL MARINE ENGINES 6LT500 6LT580 6LT640 English Greek Danish Italian German Norwegian Spanish Dutch French Portuguese Finnish Swedish...
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Page 2: California Proposition 65 Warning
We reserve the right to make any change at any time without notice. Yanmar and YANMAR registered trademarks of YANMAR MARINE INTERNATIONAL B.V. -
Page 3: 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 4 TABLE OF CONTENTS Special Warnings ................30 VC20 Starting the Engine..............32 Warm Up Mode (Shift Disconnect)............ 33 Throttle and Shift Control ..............34 Engine Speed Limit Mode ..............34 Cautions During Operation..............35 Shutting down the Engine (Stopping)..........36 Checking the Engine After Operation..........
- Page 5 TABLE OF CONTENTS Long Term Storage ................61 Preparing the Engine for Long Term Storage ........61 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 ................
- Page 6 TABLE OF CONTENTS This Page Intentionally Left Blank 6LT Series Operation Manual...
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Page 7: Introduction
If you have any marine leisure boating, the worldwide reputation of questions about these differences, please consult Yanmar Marine is second to none. We design our your authorized Yanmar Marine dealer or engines to respect nature. This means quieter distributor. -
Page 8: 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 9: 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 10: 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 11 SAFETY CAUTION WARNING Sever Hazard The safety messages that follow have CAUTION level hazards. Rotating parts can cause severe injury or death. Never wear jewelry, Poor Lighting Hazard unbuttoned cuffs, ties or Ensure that the work area is adequately loose-fitting clothing and always tie illuminated.
- Page 12 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.
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Page 13: Safety Signs
SAFETY Safety Signs NOTE: Labels containing an exclamation mark highlight a potential danger. Some warning labels shown below are affixed to the engine. Risk of burns: Lifting point (only the engine). Expulsion of pressurised hot water. Fuel filling cap Risk of burns: (on the tank, if present). - Page 14 SAFETY This Page Intentionally Left Blank 6LT Series Operation Manual...
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Page 15: 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 16: Component Identification
PRODUCT OVERVIEW COMPONENT IDENTIFICATION Right side view External blow-by filter Oil sump Starter motor Sacrificial anodes Seawater pump inlet Lifting hook 10 High-pressure pump for common rail Seawater/engine coolant heat exchanger system Air-seawater heat exchanger 11 Fuel filter Sea water delivery pipe from sea water 12 Air filter pump Figure 1... -
Page 17: Left Side View
PRODUCT OVERVIEW 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 18: Front View
PRODUCT OVERVIEW Front view Coolant expansion tank Pulley on crankshaft 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... -
Page 19: Rear View
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 20: 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 21 PRODUCT OVERVIEW EPA LABEL ON EXPANSION TANK 6LT500 6LT580 6LT640 Figure 6 6LT Series Operation Manual...
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Page 22: 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 23: Display Function
If the system does not function normally, consult your authorized Yanmar Marine dealer or distributor and ask for diagnostics. 6LT Series Operation Manual... - Page 24 PRODUCT OVERVIEW Operation of the Display’s Buttons Buttons • Act on pop-up menu (MAIN MENU) ENGINE SPEED • Perform the function 2500 OIL PRESSURE COOLANT TEMP Up Arrow moves menu selection up Down Arrow moves menu selection down ...
- Page 25 PRODUCT OVERVIEW Dimmer Linkage The same brightness as the setting of Display is applied to Switch panel and Control head. Figure 12 Auto Dimmer 2. Select “Auto dimmer limit”. (Display: Auto dimmer limit) Auto dimmer is enabled, the brightness of each device is automatically adjusted according to the ambient brightness.
- Page 26 PRODUCT OVERVIEW Switch Panel (to start and stop the engine) The switch panel has the following functions. Power switch Power switch Engine START/STOP switch Engine START/STOP switch Check Engine indicator Check Engine indicator Figure 16 To start and stop the engine: Press the START/STOP switch.
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Page 27: Station Protect
PRODUCT OVERVIEW VC20 has the following functions, which can be set in the Utility screen of MAIN MENU in the Digital Display. For more details, refer to the Vessel System Installation Manual. Station Protect It is a function to prevent the operation from the other stations while steering. •... -
Page 28: Emergency Stop
PRODUCT OVERVIEW CONTROL THE BACKUP PANEL Emergency Stop Electric Emergency Stop WARNING Only use this in an emergency. Never use the Emergency Stop switch for a normal engine shutdown. Use this switch only when 1. Pull out the protect cover. stopping the engine suddenly in an emergency. -
Page 29: Engine Management From Relay Box
PRODUCT OVERVIEW Backup Active Lamp Backup Active SW (LED color: Red) (Alternate switch) Engine Start Stop SW Shift Position SW (Momentary switch) (Alternate switch) Sub Throttle Dial Figure 21 Description Control station selector Start/stop and manual acceleration control Button not active Led not used in this version Connector for diagnostic tool ATTENTION: It is strictly prohibited to switch the... - Page 30 PRODUCT OVERVIEW Engine stop procedure 1. Move the button (2) to the STOP position until the engine has stopped completely. 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”.
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Page 31: 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. 6LT Series Operation Manual... -
Page 32: 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 33: Additional Technical Fuel Requirements
BEFORE YOU OPERATE • Even biodiesel fuels that comply with a suitable • Low temperature diesel: standard as delivered will require additional care EN 590 specifications distinguish different and attention to maintain the quality of the fuel in classes of diesel fuel, identifying the the equipment or other fuel tanks. -
Page 34: 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 35: 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 36: Preliminary Checks
ENGINE OPERATION PRELIMINARY CHECKS SPECIAL WARNINGS Each time before starting the engine: High coolant temperature • Make sure that the sea-water inlet valve is open. If high temperature is indicated by the instruments Dry operation of the seawater pump will quickly or with an alarm, reduce the engine speed and cause damage to the internal impeller. - Page 37 ENGINE OPERATION Electrical system irregularities WARNING Periodically check, especially in winter, to ensure Contamination, fire that the batteries are clean and in full working When refuelling, always make sure that no solid order, checking and topping up as indicated on or liquid pollutants enter the fuel tank;...
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Page 38: Vc20 Starting The Engine
ENGINE OPERATION VC20 STARTING THE ENGINE 1. Open the seacock. 2. Open the fuel tank cock. 3. Turn the battery switch on for engine and VC20. 4. Press the Power switch on the switch panel of the selected station (1, Figure 1). •... -
Page 39: If The Engine Fails To Start
ENGINE OPERATION If the Engine Fails to Start Before pressing the Start switch again, confirm that The engine will seize if it is operated when the engine has stopped completely. If the starter seawater discharge is too small or if load is motor is operated before the engine has completely applied without any warming up operation. -
Page 40: Throttle And Shift Control
ENGINE OPERATION THROTTLE AND SHIFT CONTROL Neutral Forward Idle Reverse Idle Panel WARNING Full speed Suddem movement hazard reverse Full speed The boat will start to move when the marine forward gear is engaged: • Ensure the boat is clear of all obstacles forward and aft. -
Page 41: Cautions During Operation
ENGINE OPERATION CAUTIONS DURING 4. Alarm buzzer sounds during operation. OPERATION If any alarm indicator with audible alarm sound appears on the display during engine operation, • Engine trouble can arise if the engine is operated stop the engine immediately. Determine the for a long time under overloaded conditions with cause and repair the problem before you the control lever in the full throttle position... -
Page 42: 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 43: Checking The Engine After Operation
ENGINE OPERATION CHECKING THE ENGINE AFTER OPERATION • Check that battery switch is turned to OFF. • Fill the fuel tank. • Close seacock(s). • If there is a risk of freezing, check that the cooling system contains enough coolant. See page 28. •... - Page 44 ENGINE OPERATION This Page Intentionally Left Blank 6LT Series Operation Manual...
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Page 45: 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 46: 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 47 INSPECTION AND MAINTENANCE Tightening Fasteners Use the correct amount of torque when you tighten fasteners on the engine. Applying excessive torque may damage the fastener or component and not enough torque may cause a leak or component failure. The tightening torque in the Standard Torque Chart should be applied only to the bolts with a “8.8”...
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Page 48: Epa Maintenance Requirements
INSPECTION AND MAINTENANCE EPA MAINTENANCE REQUIREMENTS To maintain optimum engine performance and compliance with the Environmental Protection Agency (EPA) Regulations for Engines, it is essential that you follow the Maintenance Schedule on page 43 and the Maintenance Procedures on page 45. EPA Requirements for USA and Other Applicable Countries The EPA emission regulation is applicable only in the USA and other countries that have adopted the EPA requirements in part or in whole. -
Page 49: 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 50 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.
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Page 51: Maintenance Procedures
INSPECTION AND MAINTENANCE MAINTENANCE PROCEDURES CHECK THE ENGINE OIL LEVEL Figure 1 Only check when the engine is cool and not running to avoid burns. • Using the dipstick (2), check that the oil level is between the “Min” and “Max” levels. •... -
Page 52: Check The Coolant Level
INSPECTION AND MAINTENANCE CHECK THE COOLANT LEVEL Only proceed when the engine is not running and is at low temperature in order to avoid the risk of burns. • Remove the pressure cap from the tank. • Visually check that the fluid level is a few centimeters below the filler hole. •... -
Page 53: Draining The Water From The Fuel Pre-Filter
INSPECTION AND MAINTENANCE DRAINING THE WATER FROM THE FUEL PRE-FILTER Fuel Outlet Ground Wire Fuel Inlet Air Bleed Valve Drain Valve and Water Sensor Figure 2 Only proceed when the engine is off: 1. Place a container for collecting the liquids under the pre-filter. 2. -
Page 54: Check The Electrolyte Level Of The Batteries - Clean Terminals
INSPECTION AND MAINTENANCE CHECK THE ELECTROLYTE Proceed after positioning the batteries on a horizontal surface. (Flooded lead acid batteries LEVEL OF THE BATTERIES – only) CLEAN TERMINALS WARNING Risk of damage The batteries contain sulfuric acid which is highly caustic and corrosive. Always wear gloves and protective glasses while topping up. -
Page 55: Hazard Warning
INSPECTION AND MAINTENANCE Clean terminals CLEAN THE AIR FILTER Only proceed with engine off: WARNING Hazard warning Before starting, make sure you have suitable PPE (gloves, shoes, glasses, overalls). Failure to comply with these prescriptions can result in the risk of serious injury. Check that the battery terminals and cable clamps are clean, well tightened and protected by battery terminal grease or petroleum jelly. -
Page 56: Check The State Of Corrosion Of The Zinc Anodes
INSPECTION AND MAINTENANCE CHECK THE STATE OF CORROSION OF THE ZINC ANODES Figure 5 1. Only proceed with the operation when the engine is not in operation and is at a low temperature: 1. Use suitable containers to ensure that while removing the anodes no water is released inside the hull. -
Page 57: Change The Engine Oil
INSPECTION AND MAINTENANCE CHANGE THE ENGINE OIL Figure 7 • Connect the tap to the container of the oil to be added and move the button on the panel to CHARGE until the specified quantity has been filled. • Reclose the charge/discharge tap and use the dipstick to check that the oil quantity in the sump is between the MIN and MAX limits. -
Page 58: 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 59: Change The Fuel Filter
Figure 9 To avoid the risk of burns, only proceed once the engine is stationary and has been allowed to cool. Only use original Yanmar filters. • Remove the filter (1) by unscrewing it. • Moisten the sealing gasket of the new filter with diesel or engine oil. -
Page 60: Change Fuel Pre-Filter
INSPECTION AND MAINTENANCE CHANGE FUEL PRE-FILTER Fuel Outlet Ground Wire Fuel Inlet Air Bleed Valve Drain Valve and Water Sensor Figure 10 Proceed only with the engine not running and at a low temperature to avoid any risk of burns: 1. -
Page 61: Check Tension And Condition Of Auxiliary Belt
INSPECTION AND MAINTENANCE CHECK TENSION AND CONDITION OF AUXILIARY BELT Proceed only with engine not running and at low temperature to avoid any risk of burns. • Remove the belt cover (1) from the pulley and the belt. Figure 11 Figure 12 •... -
Page 62: Change Engine Coolant
INSPECTION AND MAINTENANCE CHANGE ENGINE COOLANT Only proceed when the engine is not running and is at low temperature in order to avoid the risk of burns. • Use suitable containers to ensure that the coolant is not dispersed into the environment. •... -
Page 63: Change Air Filter
INSPECTION AND MAINTENANCE CHANGE AIR FILTER Figure 13 • Remove the filter after removing the clamp (1) indicated in the figure. • Replace the part. • Restore the correct operating conditions after having placed the filter in its seat. CHANGE OIL VAPOUR FILTERS Figure 14 Only proceed with the operation when the engine is not in operation and is at a low temperature. -
Page 64: Change Oil Vapor Filters
It is Adjustment of valve/rocker arm clearance recommended that these operations are carried out by qualified personnel belonging to the Yanmar Auxiliary component belt replacement Service Network. Consult an authorized Yanmar Cleaning of heat exchangers Marine dealer or distributor. -
Page 65: Change The Auxiliary Belt
INSPECTION AND MAINTENANCE CHANGE THE AUXILIARY BELT Figure 16 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 66 INSPECTION AND MAINTENANCE Figure 17 • Using a socket wrench (2), act on the belt tensioner (3) and remove the auxiliary belt (1). • Fit the new belt (1) on the guide rollers and onto the belt tensioner (3) using the wrench (2). •...
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Page 67: 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 To prevent the interior parts of the engine and components of the injection system from rusting or corroding, prepare the engine as follows: Arrange a place where the engine can be run at idle with a cooling water supply. -
Page 68: Engine Start-Up After Along Period Of Inactivity
LONG TERM STORAGE ENGINE START-UP AFTER A DIRECTIONS FOR THE FIRST LONG PERIOD OF INACTIVITY START-UP AND START-UP AFTER A LONG PERIOD OF 1. Change the oil and fuel filters. Drain any residual Preservative Oil from the sump. INACTIVITY 2. Fill the engine with engine oil of the type and quantity indicated in the table on page 28. -
Page 69: 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 70 ENGINE MALFUNCTIONS This Page Intentionally Left Blank 6LT Series Operation Manual...
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Page 71: 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 72 SPECIFICATIONS This Page Intentionally Left Blank 6LT Series Operation Manual...
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Page 73: Epa Warranty Usa Only
6LT Series Operation Manual EPA WARRANTY USA ONLY 6LT Series Operation Manual... -
Page 74: Your Warranty Rights And Obligations
• 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 75: Owner's Responsibility
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 76: Eu Declaration Of Conformity
EU DECLARATION OF CONFORMITY EU DECLARATION OF CONFORMITY 6LT Series Operation Manual... - Page 77 Yanmar Marine International Asia Co., Ltd. 1-32, Chayamachi, Kita-ku, Osaka 530-0013, Japan Phone: +81-6-7634-7815 Fax: +81-6-7634-7816 https://www.yanmar.com/marine Overseas Office Yanmar Asia (Singapore) Corporation Pte. Ltd. (YASC) 4 Tuas Lane, Singapore 638613 Phone: +65-6861-3855 Fax: +65-6862-5189 https://www.yanmar.com/sg/ YANMAR Marine International Americas Division 5400 118th Avenue N., Clearwater, FL 33760, USA...
- Page 78 YANMAR MARINE INTERNATIONAL B. V. 163200-99500 Issue date https://www.yanmar.com/marine...
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