Yanmar 6CXM-GTE2, Operation Manual

Page 1: ... 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 ...

Page 2: ...rectly 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 ...

Page 3: ...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 Ho...

Page 4: ...ducts 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...

Page 5: ...ly 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 op...

Page 6: ...recautions 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 sca...

Page 7: ...ng 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 1 7 MARINE DIESEL ENGINE 6CXM GTE2 1 3 Location of Product Safety Labels ...

Page 8: ... 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 ...

Page 9: ...njection 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 Alternat...

Page 10: ...RINE DIESEL ENGINE 6CXM GTE2 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 ...

Page 11: ...op the engine and to monitor its condition during operation Product Explanation 2 11 MARINE DIESEL ENGINE 6CXM GTE2 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 ...

Page 12: ...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 prob...

Page 13: ...arting 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 solen...

Page 14: ...emperature 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 bot...

Page 15: ...ter 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 ...

Page 16: ...uel 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 pr...

Page 17: ...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 3 17 MARINE DIESEL ENGINE 6CXM GTE2 3 3 Supplying Engine Lube Oil Oil port ...

Page 18: ...p 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 tan...

Page 19: ...l 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 t...

Page 20: ... 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 3 20 MARINE DIESEL ENGINE 6CXM GTE2 3 6 Checking the Lube Oil and Cooling Water ...

Page 21: ...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 make certain that any tools or cloths used in maintenance have been removed from the area Burns from Contact with Hot Engine Parts The whole engine ...

Page 22: ...l 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 1 Check the cooling water level in the sub tank If the water level is close to the lower limit remove the sub tank cap and ...

Page 23: ...ops without any change in the sub tank water level there may be some leakage of water or air In such cases consult your Yanmar dealer or distributor without delay 5 Preparing Reserves of Fuel Lube Oil and Cooling Water Have sufficient fuel ready for the day s operation In addition have a reserve of fuel lube oil and cooling water sufficient for at least one refill close to the operation area in ca...

Page 24: ... the alarm devices as shown in the diagram Before Starting are working properly Buzzer sounds Charge and other lamps light up 2 Check after starting When the key returns from the START position to ON check to see that the alarm devices as shown in the diagram After Starting are working properly Buzzer stops All of the lamps switch off By performing these procedures it can be determined whether or ...

Page 25: ...ck the position of the pointer to make sure there are no problems Tachometer Meter pointer moves to indicate revolution speed Cooling Water Temperature Meter Meter pointer in the white area is normal Pointer in the red area indicates a problem Lube Oil Pressure Meter Meter pointer in the white area is normal Pointer in the red area indicates a problem How to Operate 4 25 MARINE DIESEL ENGINE 6CXM ...

Page 26: ...h 7 Insert the key into the starter switch and turn it to ON the buzzer sounds and the alarm device lamps switch on indicating that the alarm equipment is working properly 8 Turn the key to START to start the engine When the engine has started remove your hand from the key The key will automatically return to the ON position Check to see that alarm lamps have switched off and the buzzer has stoppe...

Page 27: ... See 3 2 2 Do not hold the starter switch on for more than 15 seconds at a time If the engine does not start the first time wait for about 1 minute before trying again 4 3 4 After the Engine has Started 1 Warming up running After the engine has started let it run for about 5 minutes This warms up the engine and distributes oil to all of the parts The engine will seize if it is operated while cooli...

Page 28: ... the speed between L low speed and H high speed For a new engine be especially careful not to change speeds abruptly or attach a heavy load for the first 50 hours of operation Doing so will result in damage and shorten the life of the engine How to Operate 4 28 MARINE DIESEL ENGINE 6CXM GTE2 4 4 Adjusting the Engine Speed ...

Page 29: ...e alarm buzzer sounds during operation lower the engine speed immediately check the alarm lamps and stop the engine for repairs 5 Is there water oil or gas leakage or are there any loose bolts Check the engine room periodically for any problems 6 Is there sufficient oil in the fuel tank Replenish fuel oil in advance to avoid running out of fuel during operation 7 When operating the engine at low s...

Page 30: ...ve the key and place it in a safe place 6 Cut off the battery switch 7 Close the fuel tank cock 8 Close the Kingston cock In the rare instance that the engine does not stop when the stop button is pushed stop the engine by closing the fuel cock on the fuel tank Stopping the engine suddenly after operating at high speed or heavy loading without cooling down operation It will cause the engine temper...

Page 31: ...ng up Operation Speed Lever Governor Remote Control Handle Put in NEUTRAL Checking the Alarm Devices Turn the key for no longer than 15 seconds Remove hand from key after starting Checking for Problems for 5 minutes or longer Low Speed Position 1000 rpm or lower for 5 minutes or longer Checking the Engine During Operation Starting Operation Driving Device Clutch Clutch Remote Control Lever Driving...

Page 32: ...emote Control Handle Driving Device Clutch Clutch Remote Control Lever Speed Lever Governor Remote Control Handle Racing the Engine Speed Lever Governor Remote Control Handle Cooling down Operation Engine Stop Button Engine Stops Low Speed Position 1000 rpm or lower Put in NEUTRAL Low Speed High Speed Repeat Several Times For 5 minutes or longer ...

Page 33: ...awater and fresh water systems If the water is not drained it may freeze and damage parts of the cooling water system Draining the water from the seawater system 1 Loosen the bolts on the side cover of the seawater pump and move the cover to drain off the cooling water inside 2 Loosen the drain cock 3 After draining off the water tighten the water drain cocks and replace the side cover on the seaw...

Page 34: ...rom entering Drain bilge in the hull bottom completely Water may leak into the boat when it is moored and whenever possible it should be landed Waterproof the engine room to prevent rain and seawater from entering 5 Maintaining the Battery Charge Be sure to turn off the battery switch During long term storage charge the battery once a month to compensate for the battery s self discharge 4 8 2 Chec...

Page 35: ...dic inspections and maintenance Consult your Yanmar dealer or distributor in accordance with the service agreement Always Have Servicing Tools On Hand Keep servicing tools close to the machinery and ready for use in inspections Tightening Torque of Bolts Nuts It is important to tighten bolts and nuts properly to the correct tightening torque Over tightening damages the threads of the bolts and nut...

Page 36: ...tor Replace the fuel filter element Engine Check the quantity of lube oil lube oil Replace the lube oil 1st time 2nd time after Replace the lube oil filter bypass filter 1st time 2nd time after Clean the engine oil cooler Fresh cooling Check supply of cooling water tank water system Replace the fresh cooling water Clean check the cooling water passage Seawater Check the seawater outlet and dischar...

Page 37: ...s and replace the filters with a new one Procedure for changing the filter 1 Remove the filter using the oil filter wrench 2 Replace the filters with new ones At the same time clean the seating surface of the packing to prevent improper sealing caused by foreign material Apply a small amount of lube oil filter sealing ring 3 Check that there is no oil leakage during operation 3 Changing the bypass...

Page 38: ...in the fuel filter When water and dirt are mixed in with the fuel it becomes impossible for the fuel injection pump and the valve to work Drain periodically to keep the filter from becoming clogged 3 Drainage of oil water separator Remove the drain plug and discharge water and dirt accumulated in the oil water separator Maintenace Inspection 5 38 MARINE DIESEL ENGINE 6CXM GTE2 Fuel tank is not sup...

Page 39: ...ower limit fill with battery fluid available in the market to the upper limit If operation continues with insufficient battery fluid the battery life is shortened and the battery may overheat and explode Battery fluid tends to evaporate more quickly in the summer and the fluid level should be checked earlier than the specified times If the engine turns over at a slower than usual rate and refuses ...

Page 40: ...7 Nm 1 2 1 6kgm 5 Bleed the fuel system See 3 2 2 2 Replacing Cooling Water Cooling performance drops when the cooling water is contaminated with rust and scale Even if antifreeze or antirust is added the cooling water must be periodically replaced because the properties of the agent will degenerate Replace the cooling water periodically Draining the Cooling Water See 4 8 1 2 Supplying Cooling Wat...

Page 41: ...arings of the alternator will be damaged Be careful not to spill any oil on the V belt as this will lead to stretching and slippage 5 Inspecting and Replacing Anti Corrosive Zinc Inspect and replace the anti corrosive zinc periodically 1 Close the Kingston cock 2 Drain the cooling seawater See 4 8 12 3 Remove the plug labeled ZINC and indicated in the diagram Anti corrosive zinc is on the followin...

Page 42: ...distributor Fuel injection must be adjusted to ensure optimal engine performance 5 2 5 Inspection Every 1000 Hrs or 4 years 1 Inspecting Inner Parts of the Seawater The inside parts of the seawater pump will deteriorate with use and discharge performance drops At the specified interval or when the volume of seawater discharged is reduced inspect the seawater pump in accordance with the following p...

Page 43: ...when the cooling water is being replaced Cooling water system related parts seawater pump engine oil cooler clutch oil cooler fresh water pump fresh water cooler thermostat etc 3 Checking and Replacing the fuel pipe and the cooling water pipe This maintenance requires specialized knowledge Consult your Yanmar dealer or distributor Check the hoses of the fuel and cooling water piping and replace if...

Page 44: ...ce Inspection 5 44 MARINE DIESEL ENGINE 6CXM GTE2 5 3 Replacement Parts Name of Part Code Number Remarks Fuel filter cartridge 127695 55630 Lube oil filter cartridge 127695 35150 Lube oil bypass filter cartridge 128633 35450 Oil water separator element 127695 55760 option Rubber impeller for seawater pump 128620 42200 V belt alternator 25132 004500 ...

Page 45: ... water in the fresh water tank Leakage in the fresh water cooling system The fresh water cooling pump is damaged The inside of the C W system is dirty Insufficient engine oil Circuit broken or buzzer damaged Circuit broken or lamp burnt out Short circuit Damaged sensor or switch Measure Check battery fluid Adjust V belt tension or replace belt Ask for repairs Check and replenish the cooling water ...

Page 46: ... starter Inner parts seized or damaged Overload Insufficient fuel Boost pressure low Faulty spraying of fuel injection Excessive intake exhaust valve top clearance Insufficient fuel Faulty spraying of fuel injection Fuel injection timing off Lube oil burns excessive consumption Measure Replenish fuel bleed Bleed Replace with recommended fuel Replace the fuel filter Ask for repairs Ask for repairs ...

Page 47: ... you have a warranty problem that has not been handled to your satisfaction we suggest you take the following action Discuss your problem with a member of dealership management Often complaints can quickly be resolved at that level If the problem has already been reviewed with the Service Manager contact the owner of the dealership or the General Manager If your problem still has not been resolved...

Page 48: ... 09 Yanmar Diesel America Corp 951 Corporate Grove Drive Buffalo Grove Illinois 60089 USA Telephone 1 847 541 1900 Telefax 1 847 541 2161 Yanmar Asia Singapore Corporation Pty Ltd 4 Tuas Lane Singapore 63 8613 Telephone 65 861 5077 Telefax 65 861 5189 Telex RS 35854 YANMAR Yanmar Co Ltd Overseas Operations Division 1 Chrome 32 Chayamachi Kita Ku Osaka Japan Telephone 81 0 6 6376 6411 Telefax 81 0 ...

Page 49: ...President Yanmar Marine Int l ...

Page 50: ...President Yanmar Marine Int l ...