Yanmar 6CXM-GTE2 User manual

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Operation Manual
Yanmar Marine Diesel Engine
6CXM-GTE2
Be sure to read this manual for safe and proper operation.
Store this manual carefully after use.
DANGER
WARNING
CAUTION

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Introduction
2 | MARINE DIESEL ENGINE 6CXM-GTE2
Thank you for purchasing a Yanmar Marine
Diesel Engine.
This Operation Manual describes the operation,
maintenance, inspection and handling precautions for
the 6CXM-GTE Yanmar Marine Diesel Engine.
1. For safe operation:
Safety indications, safety precautions, explanation
and use.
2. Explanation of the product:
Specifications for this series and basic operation
principles.
3. Preparation for operation:
Fuel, lube oil, cooling water, etc., check and supply.
4. Operation:
Starting, speed regulation, stopping and long-term
storage.
5. Maintenance & inspection:
Periodic inspection, inspection items and time
period, and detailed explanation.
6. Trouble and troubleshooting:
Simple problems and table of troubleshooting
measures.
• Read this Operation Manual carefully before
operating the engine to ensure that it is used
correctly and that it stays in the best possible
condition.
• Keep this Operation Manual in a convenient place for
easy access.
• If this Operation Manual is lost or damaged, order a
new one from your dealer or distributor.
• If giving your engine to someone else, be sure to
attach this Operation Manual.
• Constant efforts are made to improve the quality
and performance of Yanmar products, so some
details included in this Operation Manual may differ
slightly from your engine. If you have any questions
about this, please contact your Yanmar dealer or
distributor.
California Proposition 65 Warning
Diesel engine exhaust and some of its constitutions are
known to the State of California to cause cancer, birth
defects and other reproductive harm.
Battery posts, terminals, and related accessories contain
lead and lead compounds, chemicals known to the State of
California to cause cancer and reproductive harm. Wash
your hands after handling.
Operation Manual
Models: Marine Engine 6XCM-GTE2
Code No. 49961-205100
All Rights Reserved, Copyright (c) YANMAR CO., LTD. 2003

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Index
3 | MARINE DIESEL ENGINE 6CXM-GTE2
1. For Safe Operation
1.1 Warning Symbols
1.2 Safety Precautions
1.3 Location of Product Safety Labels
2. Product Explanation
2.1 Use & Driving System
2.2 Engine Specifications
2.3 Location of Component
2.4 Operation Equipment
2.4. 1 Instruments
3. Before Operation
3.1 Fuel, Lube Oil and Cooling Water
3.2 Supplying Fuel
3.3 Supplying Engine Lube Oil
3.4 Supplying Cooling Water
3.5 Cranking
3.7 Checking the Lube Oil and Cooling Water
4. How to Operate
4.1 Inspection Before Starting
4.2 Checking the Instrument Panel and Alarm
Devices
4.3 Starting
4.4 Adjusting the Engine Speed
4.5 Check During Operations
4.6 Stopping the Engine
4.7 Operation Procedure
4.8 Long-Term Storage
5. Maintenance & Inspection
5.1 List of Periodic Inspections
5.2 Periodic Inspection Items
5.2.1 Inspection After Initial 50 Hrs. of Operation
5.2.2 Inspection Every 50 Hours
5.2.3 Inspection Every 250 Hrs. or 1 yr
5.2.4 Inspection Every 500 Hrs. or 2 yrs.
5.2.5 Inspection Every 1000 Hrs. or 4 yrs.
5.3 Replacement Parts
6. Trouble and Troubleshooting
6.1 Simple problems and the appropriate
countermeasures
6.2 Consulting Your Yanmar Dealer or Distributor

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For Safe Operation
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4 | MARINE DIESEL ENGINE 6CXM-GTE2
Following the precautions described in this manual
will enable you to use this engine with complete
satisfaction. Failure to observe any of the rules and
precautions, however, may result in injury, burns,
fires and engine damage. Read this manual carefully
and be sure you fully understand it before beginning
operation.
1.1 Warning Symbols
These are the warning signs, which are used in this
manual and on the products. Pay special attention to
them.
DANGER indicates an imminently hazardous
situation, which, if not avoided, WILL result in death or
serious injury.
WARNING indicates a potentially hazardous situation,
which, if not avoided, COULD result in death or serious
injury.
CAUTION indicates a potentially hazardous situation,
which, if not avoided, MAY result in minor or moderate
injury. It may also be used to alert against unsafe
practices.
The descriptions captioned by

are for
particularly important cautions for handling. If you
ignore them, the performance of your machine may
deteriorate, leading to trouble.
DANGER
WARNING
CAUTION
DANGER
WARNING
CAUTION
DANGER
WARNING
CAUTION

1.2 Safety Precautions
Precautions for Operation
Burns from Scalding
• Never remove the filler cap of the
fresh water cooler while the engine is
still hot. Steam and hot water will spurt
out and seriously burn you. Wait until
the water temperature has dropped,
then wrap a cloth around the cap and
loosen it slowly. After inspection, refasten the filler cap
firmly. If the cap is not secure, steam or scalding water
may be emitted during operation causing burns.
Proper Ventilation of the Battery Area
• Be sure the area around the battery
is well ventilated and there is nothing
which could start a fire. During
operation and charging, hydrogen gas
is emitted from the battery and can
easily be ignited.
Fires from Oil Ignition
• Be sure to use the correct type of
fuel when refueling. Mistakenly filling
with gasoline, or the like, will result in
ignition.
• Be sure to stop the engine before
refueling. If you spill fuel, wipe such
spillage carefully.
• Never place oils or other flammable material close to
the engine as this could result in ignition.
Exhaust Gas Poisoning
• Be sure to establish good ventilation
in the engine room with windows,
vents, or other ventilation equipment.
Check again during operation to be
sure that ventilation is good. Exhaust
gas contains poisonous carbon
monoxide and should not be inhaled.
Moving Parts
• Do not touch the moving parts of the
engine (propeller shaft, V-belt, PTO-
pulley, etc.) during operation or let your
clothing get caught in them as this can
result in injury.
• Never operate the engine without the
covers on the moving parts.
• Before starting the engine, check to see that any
tools or cloths used in maintenance have been
removed from the area.
For Safe Operation
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Observe these instructions
for your own safety.
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Burns from Contact with Hot Engine Parts
• The whole engine is hot during
operation and immediately after
stopping. The turbocharger, exhaust
manifold, exhaust pipe and engine are
very hot. Never touch these parts with
your body or clothing.
Alcohol
• Never operate the engine while you
are under the influence of alcohol, when
you are ill or feel unwell as this results in
accidents.
Safety Precautions for Inspection
Battery Fluid
• Battery fluid is diluted sulfuric acid.
It can blind you if it gets in your eyes,
or burn your skin. Keep the fluid away
from your body. If you get any on you,
wash it off immediately with a large
quantity of fresh water.
Fire due to Electric Short-Circuits
• Always turn off the battery switch
or detach the earth cable (-) before
inspecting the electrical system. Failure
to do so could cause short-circuiting
and fires.
Precautions for Moving Parts
• Stop the engine before you service it.
If you must inspect while the engine is
operating, never touch moving parts.
Keep your body and clothing well clear
of all moving parts as this could result
in injury.
Precautions for Removing Hot Oil and Water
to Prevent Burns
• If extracting oil from the engine while
it is still hot, do not let the oil splash
on you. To avoid getting scalded, wait
until the temperature has dropped
before removing cooling water from the
engine.
Do not alter the diesel engine.
Rebuilding the engine or altering parts to increase
the speed or the amount of fuel discharged, etc., will
make operation unsafe and result in damage and
shortening of engine life.
Disposal of waste materials
• Save oil or liquids to be disposed of in a container.
Never dispose of waste oil or other fluids outside, in a
sewer, river, or the sea.
• Treat waste materials safely observing all regulations
and laws. Ask a waste recovery company to collect
and dispose of it.
Fore Safe Operation
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To insure safe operation, product safety labels have
been attached. Their location is shown in the diagram
below. Keep the labels from becoming dirty or torn
and replace them if they are lost or damaged. Replace
labels as well when parts are replaced, ordering them
in the same manner as the parts.
Product
Safety Labels Parts Code Numbers
 128296-07300
 128296-07240
 128296-07360
 128296-07260
For Safe Operation
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1.3 Location of Product Safety Labels

2.1 Use & Driving System
This is a light, compact diesel engine for use in
pleasure boats. The engine is equipped with a
turbocharger and an intercooler, which insures
maximum output while preserving lightness and
compact size. It is imperative that the size and
structure of the boat be suited to the engine, in order
to get full performance from your engine. It is equally
important to use the correct driving device and a
propeller of the appropriate size and specifications.
The engine must be installed correctly with safe
cooling water, exhaust piping and electrical wiring.
The PTO work should be easy to use for onboard
equipment. Consult your Yanmar dealer or distributor
when selecting optional parts. When selecting optional
parts, operational and surrounding conditions should
taken into account.
Product Explanation
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Product Explanation
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2.2 Engine Specifications
Engine Model 6CXM-GTE2
Use Pleasure boat
Type Vertical water-cooled 4-cycle diesel engine
Number of cylinders-Bore X stroke mm 6-11 x 130
Displacement l7.413
Aspiration system Turbocharger
Cont. rating output kW(PS)/rpm 324(440) / 2800
High idling rpm 3250 ±25
Low idling rpm 750 ±25
Combustion system Direct injection
Starting system Electric Starting
Cooling system Constant high temperature fresh water-cooling
Lubrication system Forced lubrication system with gear pump
Direction of rotation (When viewed
from stern side) Crankshaft Counterclockwise viewed from flywheel side
Fuel injection pump In-line type
Fuel injection valve Hole type
Turbocharger Holset HX50
Electric devices
Starter 12V-4.8kW
Alternator 12V-55A
Battery 12V-200Ah
Lube oil capacity lEngine oil (oil pan)
Full/effective 22.8
Cooling water capacity System 20
Sub-tank 1.5
Dimension (LXWXH) mm 1190 x 805 x 905
Dry Mass kg 825

2.3 Location of Component
Product Explanation
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Turbocharger Engine plate Fresh water pump
Fresh water tank
Fuel filter
Lube oil
bypass filter Starter Lube
oil cooler
Lube oil filter Seawater pump
Intercooler
Fuel injection
pump
As seen from A
Fresh water
cooler Alternator

2.4 Operation Equipment
2.4.1 Instruments [Option]
The instrument panel is located in the cockpit,
separate from the engine. The following instruments
enable you to start and stop the engine and to monitor
its condition during operation.
Product Explanation
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 Tachometer
 Hour meter
 C.W. temp. meter
 L.O. temp. meter
 Boost press. meter
 Alarm lamps
 Starter switch
 Stop button switch
 Buzzer stop switch
 Alarm buzzer
 Illumination switch
 Quartz clock
Explanation of the equipment
used to operate the engine.
New C type
New D type

(1) Meters
The following meters are located in the upper center
part of the instrument panel.
 New C/D type panels use analog electric systems
and have a pointer indicator. Turn the panel illumination
switch ON for easy viewing.
• Tachometer
The engine’s rotation speed is indicated. Load and
engine rotation can be monitored.
• Hour meter
The number of hours of operation is indicated, and
can be used as a guide for periodic maintenance
checks.
• Cooling Water Temperature Meter
The cooling water temperature is indicated. Enables
monitoring of the cooling condition of the engine.
• Lube Oil Pressure Meter
The engine oil pressure is indicated. Enables
monitoring of the condition of the engine’s lube oil
pressure.
• Boost Press. Meter
The air intake pressure is indicated
(2) Alarm Devices
When there is some problem during operation, such
as battery charge failure, abnormal fresh cooling water
temperature, abnormal lube oil pressure, the alarm
buzzers will sound and lamps will light up.
• Alarm buzzers
When the various alarm lamps light up, the alarm
buzzers will switch on at the same time and sound at
intervals. However, no alarm buzzer will sound when
the charge lamp lights up.
• Buzzer stop switch
When the buzzer sound is no longer necessary, it
can be turned off with the buzzer stop switch.
• Alarm lamps
The alarm monitor window indicates the trouble
spot when one of the symbols shown below lights
up. When operation is normal, the alarm lights are
off. However, should some problem arise, then the
sensors will pick it up and cause the light behind the
appropriate symbol to switch on.
1 Battery Charge
When the charge is abnormal, the lamp will light
up. When charging begins, the lamp will switch off.
(Alarm buzzer will not sound when the lamp lights up.)
2 C.Water Temp.
When the temperature of the cooling fresh water
exceeds the maximum (95°C or higher), the lamp
will light up. Continuing operation at temperatures
exceeding the maximum level will result in damage and
seizure. Check the load and the fresh water-cooling
system for any abnormalities.
3 Lub. Oil Press.
When the lube oil pressure falls below normal
level, the oil pressure sensor will register this
and the lamp will light up. Continuing operation with
insufficient oil will result in damage and seizure. Check
the oil level.
Product Explanation
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4 Lub. Oil Filter
When the lube oil filter is clogged, the lamp will
light up. Replace the lube oil filter.
(3) Starter Switch
This is the main switch for starting engine operation. It
is a rotary-type, 3-step switch. Turning the key in the
switch changes position.
OFF is the position at which the engine is stopped.
All current is cut off. The key can be inserted and
removed in this position.
ON is the position for operation. Current flows to the
instruments and alarm devices.
START is the position for starting. When the starter
turns, the engine starts.
When you remove your hand the key returns
automatically to the ON position.
GLOW is the position for turning on the air heater. The
air heater aids starting during cold conditions by
warming up the intake air before starting.
(4) Stop button
Pushing the stop button on the right of the control
panel stops the engine. When the stop button is
pushed, the solenoid valve on the fuel injection pump
works to cut off the fuel supply and stop the engine.
Continue to push the stop button until the engine has
come to a complete stop.
Product Explanation
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Starter switch
Stop position
Drive position
Starting position
Stop button

3.1.1 Fuel
(1) Selection of Fuel
Use the following diesel fuels or equivalents. Select
fuels of a higher quality for best engine performance.
Diesel fuel standard for various countries
ISO 8217 DMA
*ASTM D 975 Grade No.1-D or No.2-D
JIS K2204 Grade No.2,
No.3 or special-No.3
BS 2869 Part-1 class-A1 or A2
At low temperatures, fuel becomes difficult to ignite
and will not flow easily, making starting difficult. Select
fuel of a cetane of 45 or greater to insure ignitability,
and use the outside temperature as a guide for
selecting the proper grade to insure fluidity.
When other than the specified fuel is
used, the engine will not perform to full capacity and
parts may be damaged.
(2) Fuel Piping
Install the fuel pipe from the fuel tank to the fuel pump
in accordance with the following diagram. Be sure to
attach a drain cock to the fuel tank to enable dirt and
water, which have settled at the bottom of the tank to
be drained off.
Before operation
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Perform items 3.1-3.6 before
starting to prepare for operation.
Fuel feed pump
Fuel return pipe
Fuel tank
Drain cock
Fuel oil cock
Less than
500 mm
3.1 Fuel, Lube Oil and Cooling Water

To fuel oil strainer

3.1.2 Lube oil
(1) Selection of Engine Lube Oil
Use the following lube oil:
API Classification CD
Standards of American Petroleum Institute
SAE Viscosity 15W40
Standards of Society of Automotive Engineering
Using other than the specified lube oil
will lead to seizure of parts inside the engine and gear
device, abnormal wear, and shorten engine life. It will
also affect the starting ability and power output.
(2) Handling the Lube Oil
• When handling and storing lube oil, be careful not
to allow dust and water to enter the lube oil. Clean
around the filler port before refilling.
• Do not mix lube oils of different types or brands.
Mixing may reduce the lubricating performance
3.1.3 Fresh Cooling Water
• Always use soft water (tap water) for the fresh water.
Never use dirty water or hard water. Impurities in
the cooling water cause scale and rust to build up in
the cooling system reducing cooling efficiency and
causing the engine to overheat.
• During the cold season, add antifreeze to the cooling
water to prevent freezing.
• Failure to add antifreeze will result in damage to
various parts in the cooling water system.
• Consult your Yanmar dealer or distributor on the use
of antifreeze and detergents.
• Refer to the instructions accompanying the
antifreeze for the proper mixing ratio.
Select the ratio for the lowest temperature of the
cold season. If the mixture is toothick, the cooling
efficiency will be reduced.
• Do not mix different brands of antifreeze. Mixing
reduces cooling efficiency and leads to parts
damage.
• When the amount of cooling water is too low, refill
with fresh water only.
Before operation
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3.2 Supplying Fuel
Fires from Oil Ignition
• Be sure to use the correct type of
fuel when refueling. Mistakenly filling
with gasoline, or the like, will result in
ignition.
• Be sure to stop the engine before
refueling. If you spill fuel, wipe such spillage carefully.
• Never place oils or other flammable material close to
the engine as this could result in ignition.
3.2.1 Filling the Fuel Tank
Fill the tank with clean fuel, which has not been
contaminated with water or dust. Fill the tank to
approximately 90% pf its capacity, and take care not
to let the fuel spill over during operation.
3.2.2 Bleeding the Fuel System
Bleed the fuel system according to the following
procedure. When there is air in the fuel system, the fuel
injection pump will not be able to function.
The fuel system includes the fuel tank, water
separator, fuel oil filter, feed pump, fuel injection pump,
high-pressure pipe and fuel injection valve.
If air enters this system, fuel cannot be injected. Bleed
air from the fuel system completely by using the
following procedure:
1 Open all the shut-off valves of the fuel system.
2 Loosen the air bleeding plug of the fuel injection
pump.
3 Loosen the bleeding bolts on the fuel oil filter.
4 Pump the priming knob. When the fuel coming out
of the air-bleeding opening is clear (no more air
bubbles visible) tighten the air bleeding bolts.
Before operation
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Air bleeding plug
Injection pump
Feed pump
Priming knob

1) Lube oil supply to oil pan
Remove the oil port cap from the side plate and supply
lube oil as shown in the photo below.
2) Checking the oil level
Insert the dipstick completely and check the oil level.
If the oil level is lowered, supply lube oil up to the
maximum level mark (upper mark) on the dipstick.
3) Replace the dipstick and tighten the oil inlet cap
firmly by hand.
Do not overfill.
Overfilling will cause oil to be sprayed out from
the breather during operation and lead to engine
problems.
Before operation
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3.3 Supplying Engine Lube Oil
Oil port
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3.4 Supplying Cooling Water
Burns from Scalding
• Never remove the filler cap of the fresh
water cooler while the engine is still hot.
Steam and hot water will spurt out and
seriously bum you. Wait until the water
temperature has dropped, then wrap a
cloth around the cap and loosen it slowly.
• After inspection, refasten the cap firmly. If the cap is
not secure, steam or scalding water may be emitted
during operation, causing burns.
Fill the fresh water tank and the sub-tank with fresh
cooling water.
1 Before filling, check to be sure the drain cocks
(indicated in the photo’s) are closed.
2 Remove the filler cap of the fresh water tank by
turning the cap counterclockwise 1/3 of a turn.
3 Pour cooling water slowly into the fresh water tank
so that air bubbles do not develop. Supply until the
water overflows from the filler port.
4 After supplying cooling water, replace filler cap and
tighten it firmly. To replace the cap, align the detents
on the bottom of the cap with the notches on the
filler port and turn clockwise 1/3 of a turn.
5 Remove the sub-tank cap and fill with water to the
upper limit, FULL. Replace cap.
6 Check the rubber hose connecting the sub-
tank to the fresh water cooler. Be sure the
hose is securely connected and there is no
looseness or damage. When the hose is not
watertight, an
excessive amount
of cooling water wil
l be used.
Before operation
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Upper limit
Lower limit
To fresh water tank Filler cap
Drain cock
Drain cock
18 | MARINE DIESEL ENGINE 6CXM-GTE2
Drain cock
Filler cap

3.5 Cranking
When the engine is being used for the first time or if it
has not been used for a long period of time, perform
cranking before starting to distribute oil to all of the
parts. Using an engine which has been stored for a
long period of time without the cranking procedure
may result in engine seizure, since there will no longer
be oil on the moving parts after storage.
1 Open Kingston cock.
2 Cut off all clutches and the main switch, making
sure that all auxiliary machines are in a no-load
position.
3 Put marine gear in NEUTRAL
4 Crank the engine. Push the stop button to stop fuel
ignition while starting.
1) Put the key into the starter switch.
2) While pushing the stop button, turn the key to
the START position and hold it there. The engine
will begin turning. If you remove your hand from
the stop button, the engine will start. Do not take
your hand off the button.
5 Continue cranking the engine for about 5 seconds,
checking for abnormal sounds.
6 Return the key to the OFF position. The engine will
stop.
Before operation
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Starter switch
Stop position
Drive position
Starting position

When lube oil, gear oil, and cooling water are put in for
the first time, or after they have been replaced, their
levels should be checked after a trial operation. Oil and
water will be distributed to the various parts during
the operation, lowering the levels of oil and water.
Replenish to the proper amounts.
[204]
• Supplying engine lube oil:  See 3.3
• Supplying cooling water:  See 3.4
Before operation
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3.6 Checking the Lube Oil and Cooling Water