Yanmar 6SY Series User manual

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

Disclaimers:
We reserve the right to change specifications and to improve our products without notice or
obligation.
All information, illustrations and specifications in this manual are based on the latest
information available at the time of publishing. The illustrations used in this manual are
intended as representative reference views only. Moreover, because of our continuous
product improvement policy, we may modify information, illustrations and / or specifications
to explain and / or exemplify a product, service or maintenance improvement. We reserve
the right to make any change at any time without notice. Yanmar and are
registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other
countries.
All Rights Reserved:
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and retrieval systems - without the written permission of Yanmar Marine International.
© 2006 Yanmar Marine International
1006
ii 6SY Operation Manual

INTRODUCTION
Welcome to the world of Yanmar Marine!
Yanmar Marine offers engines, drive
systems and accessories for all types of
boats, from runabouts to sailboats, and from
cruisers to mega yachts. In marine leisure
boating, the worldwide reputation of Yanmar
Marine is second to none. We design our
engines to respect nature. This means
quieter engines, with minimal vibrations,
cleaner than ever. All of our engines
designed after 1996 meet most of the
present and future emission regulations,
such as BSO II, SAV, EPA II, IMO and RCD.
To help you enjoy your Yanmar 6SY engine
for many years to come, please follow these
recommendations:
• Read and understand this Operation
Manual before you operate the machine
to ensure that you follow safe operating
practices and maintenance procedures.
• 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
authorized Yanmar marine dealer or
distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should
be considered a permanent part of the
engine and remain with it.
• 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 these differences, please contact
your authorized Yanmar marine dealer or
distributor.
• The specifications and components
(instrument panel, fuel tank, etc.)
described in this manual may differ from
ones installed on your vessel. Please refer
to the manual provided by the
manufacturer of these components.
6SY Operation Manual iii

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:
INTRODUCTION
iv 6SY Operation Manual

TABLE OF
CONTENTS
Page
Safety ....................................................................... 1
Safety Precautions ................................................. 2
General Information ......................................... 2
Before You Operate ......................................... 2
During Operation and Maintenance ..................... 2
Safety Decals ....................................................... 7
Product Overview ...................................................... 9
Yanmar 6SY Features and Applications ...................... 9
Component Identification ........................................ 10
Nameplate .......................................................... 12
Engine Nameplate (Typical) ............................. 12
Function of Major Components ................................ 13
Engine Management System (EMS S6) ..................... 14
Positions of Sensors for EMS with S6 ................. 14
Rotation Speeds ............................................ 15
Redundant Throttle Mode ................................ 15
Coolant Temperature ...................................... 15
Oil Pressure .................................................. 15
Before You Operate .................................................. 17
Diesel Fuel .......................................................... 17
Diesel Fuel Specifications ................................ 17
Filling the Fuel Tank ........................................ 18
Bleeding the Fuel System ................................ 19
Engine Oil ........................................................... 20
Engine Oil Specifications ................................. 20
Engine Oil Viscosity ........................................ 20
Checking the Engine Oil .................................. 21
Adding Engine Oil .......................................... 21
Selection of Marine Gear Oil ............................. 21
6SY Operation Manual v

Engine Coolant ..................................................... 22
Engine Coolant Specifications ........................... 22
Coolant (Closed Cooling System) ...................... 22
Checking the Coolant Level .............................. 22
Daily Checks ....................................................... 23
Visual Checks ............................................... 23
Check for Fuel, Engine Oil and Engine Coolant
Leaks .......................................................... 24
Check Diesel Fuel, Engine Oil and Engine Coolant
Levels .......................................................... 24
Checking and Refilling Marine Gear Oil ............... 24
Checking the Battery Charge ............................ 24
Cleaning the Battery ....................................... 25
Checking the Battery Electrolyte Level ................ 25
Checking the Alternator Belt ............................ 25
Checking the Alarm Indicators ........................... 25
Preparing Fuel, Oil and Coolant in Reserve .......... 25
Engine Operation ...................................................... 27
Starting the Engine ................................................ 29
Starting at Low Temperatures ........................... 29
Shutting Down the Engine ....................................... 30
Checking the Engine After Operation ......................... 30
Periodic Maintenance ................................................ 31
Safety Precautions ................................................ 31
Precautions ......................................................... 33
The Importance of Periodic Maintenance ............. 33
Performing Periodic Maintenance ...................... 33
The Importance of Daily Checks ........................ 33
Keep a Log of Engine Hours and Daily Checks ..... 33
Yanmar Replacement Parts .............................. 33
Tools Required .............................................. 33
Tightening Fasteners ...................................... 33
Ask Your Authorized Yanmar Marine Dealer or
Distributor For Help ........................................ 33
Required EPA Maintenance USA Only ................ 34
EPA Requirements USA Only ........................... 34
EPA Requirements ................................................ 34
Conditions to Ensure Compliance with EPA
Emission Standards ........................................ 34
Inspection and Maintenance ............................. 35
Periodic Maintenance Schedule ............................... 35
Engines with Low Operating Hours ..................... 36
TABLE OF CONTENTS
vi 6SY Operation Manual

Inspection and Maintenance for EPA Emission-
Related Parts ................................................ 39
Maintenance Procedures ........................................ 40
After Initial 50 Hours of Operation ...................... 40
Every 50 Hours of Operation ............................. 46
Every 250 Hours of Operation ........................... 47
Every 500 Hours of Operation ........................... 56
Every 1000 Hours of Operation ......................... 57
Every 2000 Hours of Operation ......................... 58
Long-Term Storage ................................................... 59
Prepare Engine for Long-Term Storage ...................... 59
Specifications .......................................................... 61
Principal Engine Specifications ................................ 61
EPA Warranty USA Only ............................................ 63
Yanmar Co., Ltd. Limited Emission Control System
Warranty - USA Only ............................................. 63
Your Warranty Rights and Obligations: ................ 63
Warranty Period: ............................................ 63
Warranty Coverage: ........................................ 64
Exclusions: ................................................... 64
Owner’s Responsibility: ................................... 64
Customer Assistance: ..................................... 64
TABLE OF CONTENTS
6SY Operation Manual vii

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TABLE OF CONTENTS
viii 6SY Operation Manual

SAFETY
Yanmar considers safety of great
importance and recommends that anyone
that comes into close contact with its
products, such as those who install,
operate, maintain or service Yanmar
products exercise care, common sense and
comply with the safety information in this
manual and on the machine’s safety decals.
Keep the decals from becoming dirty or torn
and replace them if they are lost or
damaged. Also, if you need to replace a part
that has a decal attached to it, make sure
you order the new part and decal at the same
time.
!
This safety alert symbol appears
with most safety statements. It
means attention, become alert,
your safety is involved! Please
read and abide by the message
that follows the safety alert
symbol.
!
DANGER
Indicates a hazardous situation which, if
not avoided, will result in death or
serious injury.
!
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or
serious injury.
!
CAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or
moderate injury.
NOTICE
Indicates a situation which can cause
damage to the machine, personal property
and / or the environment or cause the
equipment to operate improperly.
6SY Operation Manual 1

SAFETY PRECAUTIONS
General Information
There is no substitute for common sense
and careful practices. Improper practices or
carelessness can cause burns, cuts,
mutilation, asphyxiation, other bodily injury
or death. This information contains general
safety precautions and guidelines that must
be followed to reduce risk to personal safety.
Special safety precautions are listed in
specific procedures. Read and understand
all of the safety precautions before operation
or performing repairs or maintenance.
Before You Operate
!
DANGER
The safety messages that follow have
WARNING level hazards.
NEVER permit anyone to
install or operate the
engine without proper
training.
• Read and understand this Operation
Manual before you operate or service the
engine to ensure that you follow safe
operating practices and maintenance
procedures.
• Safety signs and decals are additional
reminders for safe operating and
maintenance techniques.
• See your authorized Yanmar marine
dealer or distributor for additional training.
During Operation and
Maintenance
!
DANGER
The safety message that follows has
DANGER level hazards.
Crush Hazard
NEVER stand under hoisted
engine. If the hoist mechanism
fails, the engine will fall on you.
SAFETY
26SY Operation Manual

!
WARNING
The safety messages that follow have
WARNING level hazards.
Explosion Hazard
Avoid serious personal injury
or equipment damage. While
the engine is running or the
battery is charging, hydrogen
gas is being produced and can
be easily ignited. Keep the area around the
battery well-ventilated and keep sparks,
open flames and any other form of ignition
out of the area.
Fire and Explosion Hazard
Diesel fuel is flammable and explosive
under certain conditions.
NEVER use a shop rag to catch the fuel.
Wipe up all spills immediately.
NEVER refuel with the engine running.
Store any containers containing fuel in a
well-ventilated area, away from any
combustibles or sources of ignition.
NEVER place diesel fuel or other flammable
material such as oil, hay or dried grass close
to the engine during engine operation or
shortly after shut down.
Fire Hazard
Avoid injury or equipment
damage from fire. Undersized
wiring systems can cause an
electrical fire.
Sever Hazard
Rotating parts can cause
severe injury or death. NEVER
wear jewelry, unbuttoned
cuffs, ties or loose fitting
clothing and ALWAYS tie long
hair back when working near moving /
rotating parts such as the flywheel or PTO
shaft. Keep hands, feet and tools away from
all moving parts.
Alcohol and Drug Hazard
NEVER operate the engine
while under the influence of
alcohol or drugs or feeling ill.
Exposure Hazard
To avoid injury, ALWAYS
wear personal protective
equipment including
appropriate clothing, gloves,
work shoes, eye and hearing
protection as required by the task at hand.
SAFETY
6SY Operation Manual 3

!
WARNING
Entanglement Hazard
NEVER leave the key in the
key switch when you are
servicing the engine.
Someone may accidentally
start the engine and not realize
you are servicing it.
Avoid personal injury. NEVER operate the
engine while wearing a headset to listen to
music or radio because it will be difficult to
hear the warning signals.
Stop the engine before you begin to service
it.
If you must service the engine while it is
operating, remove all jewelry, tie back long
hair, and keep your hands, other body parts
and clothing away from moving / rotating
parts.
Piercing Hazard
Avoid skin contact with high
pressure diesel fuel spray
caused by a fuel system leak
such as a broken fuel injection
line. High pressure fuel can
penetrate your skin and result in serious
injury. If you are exposed to high pressure
fuel spray, obtain prompt medical treatment.
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. High pressure hydraulic fluid can
penetrate your skin and result in serious
injury. If you are exposed to high pressure
hydraulic fluid spray, obtain prompt medical
treatment.
Burn Hazard
Avoid serious injury. Some of
the engine surfaces become
very hot during operation and
shortly after shut-down. Keep
hands and other body parts
away from hot engine
surfaces.
Sudden Movement Hazard
Avoid personal injury. ALWAYS stop the
engine before beginning service.
Exhaust Hazard
Avoid serious injury or death.
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.
SAFETY
46SY Operation Manual

!
CAUTION
The safety messages that follow have
CAUTION level hazards.
Poor Lighting Hazard
Avoid personal injury or equipment damage.
Ensure that the work area is adequately
illuminated. ALWAYS install wire cages on
portable safety lamps.
Tool Hazard
Avoid personal injury or equipment damage.
ALWAYS use tools appropriate for the task
at hand and use the correct size tool for
loosening or tightening machine parts.
Flying Object Hazard
Avoid personal injury. ALWAYS wear eye
protection when servicing the engine or
when using compressed air or high-
pressure water. Dust, flying debris,
compressed air, pressurized water or steam
may injure your eyes.
Coolant Hazard
Wear eye protection and
rubber gloves when you
handle Long Life engine
coolant. If contact with the
eyes or skin should occur,
flush eyes and wash immediately with clean
water.
NOTICE
The safety messages that follow have
NOTICE level hazards.
It is important to perform daily checks as
listed in the Operation Manual.
Periodic maintenance prevents unexpected
downtime, reduces the number of accidents
due to poor engine performance and helps
extend the life of the engine.
See your authorized Yanmar marine dealer
or distributor if you need to operate the
engine at high altitudes. At high altitudes the
engine will lose power, run rough and
produce exhaust gases that exceed the
design specifications.
ALWAYS be environmentally
responsible.
Follow the guidelines of the EPA or other
governmental agencies for the proper
disposal of hazardous materials such as
engine oil, diesel fuel and engine coolant.
Consult the local authorities or reclamation
facility.
NEVER dispose of hazardous materials by
dumping them into a sewer, on the ground
or into ground water or waterways.
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
chamber causing excessive engine speed,
white exhaust smoke and serious engine
damage. This applies to engines that run
continuously or those that run for short
periods of time.
SAFETY
6SY Operation Manual 5

NOTICE
If you have an installation with two or three
engines and only one engine is operating,
the water pickup (thru-hull) of the non-
running engine(s) should be closed. This will
prevent water from being forced past the
seawater pump and eventually finding its
way into the engine. The result of water
entering the engine could cause seizure or
other serious problems.
If you have an installation with two or three
engines and only one engine is operating,
please note that if the propeller shaft thru-
hull (stuffing box) is lubricated by engine
water pressure and the engines are
interconnected, care must be taken that
water from the running engine does not
enter the exhaust of the non-running engine
(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
engines and only one engine is operating, it
is important to limit the amount of throttle
applied to the running engine. If you observe
black smoke or movement of the throttle
does not increase engine rpm, you are
overloading the engine that is running.
Immediately throttle back to approximately
2/3 throttle or to a setting where the engine
performs normally. Failure to do so may
cause the running engine to overheat or
cause excess carbon buildup which may
shorten the engine's life.
SAFETY
66SY Operation Manual

SAFETY DECALS
securely attached.
CAUTION !
When connecting the seawater
pipes make sure they are
0004481
DANGER
DANGER
CAUTION
CAUTION
Figure 1
SAFETY
6SY Operation Manual 7

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SAFETY
86SY Operation Manual

PRODUCT OVERVIEW
YANMAR 6SY FEATURES
AND APPLICATIONS
The 6SY is a four-stroke, six-cylinder direct
injection diesel engine. The engine is
turbocharged and equipped with a charge
air cooler containing a liquid cooling system.
The engine has a heat exchanger which is
cooled by a seawater coolant system.
The engine is designed for pleasure craft
use.
In order to obtain full performance from your
engine, it is imperative that you check the
size and structure of the hull and use a
propeller of the appropriate size. As new
boats are used, owners add additional
equipment and completely fill the fuel and
water tanks adding to the overall
displacement (weight) of the vessel. Extra
canvas enclosures, bottom paint, and
bottom fouling can add additional hull
resistance. It is recommended that a new
vessel be propped so the engine can
operate at 100 rpm above maximum rpm to
allow for some added weight and hull
resistance. Failure to do so can lead to
reduced vessel performance, increased
smoke levels and cause permanent
damage to your engine.
The engine must be installed correctly with
coolant lines, exhaust gas lines and
electrical wiring. Any auxiliary equipment
attached to the engine should be easy to use
and accessible for service. To handle the
drive equipment, propulsion systems
(including the propeller) and other on-board
equipment, always observe the instructions
and cautions given in the operation manuals
supplied by the shipyard and equipment
manufacturers.
The laws of some countries may require hull
and engine inspections, depending on the
use, size and cruising area of the boat. The
installation, fitting and surveying of this
engine all require specialized knowledge
and engineering skills. See Yanmar's local
subsidiary in your region or your authorized
Yanmar marine dealer or distributor.
6SY Operation Manual 9

COMPONENT IDENTIFICATION
Figure 1 illustrates a typical version of a 6SY engine. Your engine may have different
equipment from that illustrated.
0004473
(25)
(23)
(24)
(22)
(21)
(18)
(10) (9)
(7)
(4)
(3)
(2)
(5)
(6)
(16)
(14)
(13)
(26)
(1)
(11)
(12)
(17) (19)
(27)
(20)
(15)
(8)
Figure 1
PRODUCT OVERVIEW
10 6SY Operation Manual

1 – Air Filter
2 – Coolant Filler Cap
3 – Coolant Recovery Tank
4 – Engine Oil Filler Cap
5 – Engine Number, Stamped into the
Engine Block
6 – Nameplate
7 – Coolant Pump
8 – Coolant Drain
9 – Engine Oil Filter
10 – Engine Oil Cleaner
11 – Engine Oil Dipstick
12 – Engine Oil Drain
13 – Heat Exchanger
14 – Seawater Outlet
15 – Seawater Inlet
16 – Seawater Pump
17 – Charge Air Cooler
18 – Closed Crankcase Ventilation Filter
19 – Turbocharger (Water-Cooled)
20 – Fuel Filter
21 – Fuel Pump
22 – Starter Motor
23 – Alternator (1 Standard, 2nd Optional)
24 – Engine Oil Pressure Sensor
25 – Control Unit (EMS S6)
26 – Marine Gear Oil Cooler
27 – Charge Air Cooler
PRODUCT OVERVIEW
6SY Operation Manual 11

NAMEPLATE
Figure 2 shows the location of regulatory
information on Yanmar 6SY marine engines.
Engine Nameplate (Typical)
6SY Engines
MODEL
CONT. RATING kW rpm
rpm
MAX OUTPUT kW
ENGINE NO.
YANMAR DIESEL ENGINE
0003496
Figure 2
PRODUCT OVERVIEW
12 6SY Operation Manual