Yanmar 6LT Series, Operation Manual

Page 1: ...view 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 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 ...

Page 2: ... Check the Engine Oil Level 45 Check the Oil Level in the Marine Gear 45 Check the Coolant Level 46 Check the Condition of the Exhaust Duct s 46 Draining the Water From the Fuel Pre filter 47 Check the Electrolyte Level of the Batteries Clean Terminals 48 Clean the Air Filter 49 Check the State of Corrosion of the Zinc Anodes 50 Change the Engine Oil 51 Change Engine Oil Filters 52 Change the Fuel...

Page 3: ...aring 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 63 Specifications 65 EPA Warranty USA Only 67 EU Declaration of Conformity 70 ...

Page 4: ...TABLE OF CONTENTS iv 6LT Series Operation Manual This Page Intentionally Left Blank ...

Page 5: ... 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 ...

Page 6: ...No ___________________________________________________________________ Date Purchased ____________________________________________________________________ Dealer ____________________________________________________________________________ Dealer Phone ______________________________________________________________________ Q To Register Your Yanmar Engine 1 Visit https yanmar microsoftcrmportals com...

Page 7: ...ched to it make sure you order the new part and label at the same time 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 situatio...

Page 8: ...igns and labels are additional reminders for safe operating and maintenance techniques Consult authorized Yanmar Marine dealer or distributor for additional training During Operation and Maintenance WARNING The safety messages that follow have WARNING level hazards Explosion Hazard While the engine is running or the battery is charging hydrogen gas is being produced and can be easily ignited Keep ...

Page 9: ...y after shutdown Keep hands and other body parts away from hot engine surfaces Exhaust Hazard 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 CAUTION The safety messages that follow have CAUTION le...

Page 10: ...llation 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 ...

Page 11: ... highlight a potential danger Lifting point only the engine Risk of burns Expulsion of pressurised hot water Fuel filling cap on the tank if present Risk of burns Presence of parts at high temperature Engine oil filling cap Risk of fire Presence of fuel Engine oil level dipstick Risk of injury from moving parts Presence of fans pulleys belts or other ...

Page 12: ...SAFETY 8 6LT Series Operation Manual This Page Intentionally Left Blank ...

Page 13: ...propulsion systems including the propeller and other inboard equipment always observe the instructions and cautions given in the operation manuals supplied by the boatyard and equipment manufacturers The 6LT common rail series engines are designed to be operated at maximum throttle 1 for less than 5 of total engine time 30 minutes out of every 10 hours and at maximum cruising speed or less the res...

Page 14: ...ght side view 1 Air filter 2 Fuel filter 3 High pressure pump for common rail system 4 Seawater pump inlet 5 Air seawater heat exchanger 6 Sacrificial anodes 7 Lifting eye 8 Coolant Filler Cap 9 Engine coolant seawater heat exchanger 10 Starter motor 11 Seawater Drain Figure 1 ...

Page 15: ... 11 Left side view 1 Oil filters 2 Coolant expansion tank 3 Oil level dipstick 4 Oil filler cap 5 Lifting eye 6 Electronic control unit 7 Exhaust and seawater outlet 8 Turbocharger 9 Oil sump 10 Oil drain plug 11 Oil sump evacuation pump Figure 2 ...

Page 16: ...ansion tank 2 Oil filter 3 Thermostat body 4 Coolant inlet pipe going to engine water pump 5 Oil evacuation pump 6 Engine mounts 7 Pulley on crankshaft 8 Oil sump 9 Seawater pump inlet 10 Engine coolant seawater heat exchanger 11 Blow by gas valve 12 Oil filler cap Figure 3 ...

Page 17: ...peration Manual 13 Rear view 1 Air filter 2 Fuel Pipes 3 Seawater pump inlet 4 Engine mounts 5 Engine flywheel 6 Oil sump 7 Turbine geometry actuator 8 Coolant expansion tank 9 Turbocharger 10 Oil filler cap 11 Intake pipe Figure 4 ...

Page 18: ...PRODUCT OVERVIEW 14 6LT Series Operation Manual NAMEPLATES IDENTIFICATION DATA The plates are fixed to the engine coolant tank Figure 5 6LT500 6LT580 6LT640 ENGINE NAMEPLATE LABEL ON EXPANSION TANK ...

Page 19: ...PRODUCT OVERVIEW 6LT Series Operation Manual 15 Figure 6 6LT500 6LT580 6LT640 EPA LABEL ON EXPANSION TANK ...

Page 20: ...ot 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 The system has many functions that must be configured and calibrations must be mad...

Page 21: ...rized Yanmar Marine dealer or distributor and ask for diagnostics Diag Codes Screen Figure 10 Alarm Indicator Functions The alarm indicators and buzzer are activated when sensors detect an abnormality during engine operation The alarm indicators are off during normal operation but are activated as follows when an abnormality arises The coolant temperature alarm indicator activates when the coolant...

Page 22: ...detail information indication function is displayed Display the related setting screen of the relevant icon If there are multiple items execute with the ENTER button after selecting with the buttons Adjusting Brightness Press the button Display the brightness adjustment screen and adjust brightness with the buttons Manual dimmer mode only Switching Night Mode Press the button Switch to the night m...

Page 23: ...isplay Auto dimmer limit Figure 14 3 Set the minimum and maximum brightness as required The brightness is adjusted in 8 steps Figure 15 OIL PRESSURE COOLANT TEMP 0 0 0 MAIN MENU Alarms DIAGs Display Engine speed Monitor settings Synchro Utility Choices Split window Window select Brightness Night mode Auto dimmer Auto dimmer limit YES NO OIL PRESSURE COOLANT TEMP 0 0 0 MAIN MENU Alarms DIAGs Displa...

Page 24: ...ption Use this switch only in an emergency Figure 17 NOTICE 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 Power switch Engine START STOP switch Check Engine indicator Power switch Engine START STOP s...

Page 25: ...tem power is turned off the selected Sys on by ID and Start by ID cannot be disabled and it is required to enter the Owner ID at each time After entering the ID and verification if you don t operate for 10 seconds the entry becomes invalid and it is required to enter the Owner ID again Owner ID Change The ID used in Sys on by ID and Start by ID can be set and changed as follows If you select Owner...

Page 26: ...NG Only use this in an emergency 1 Pull out the protect cover 2 Check that the power switch on the switch panel is OFF and that the control head handle and backup panel s shift switch are in the N Neutral position 3 Press the power switch to the ON position on the backup panel The lamp will come and control by the backup panel is enabled 4 The engine can be started or stopped with the START STOP s...

Page 27: ...reby enabling the adjacent START STOP 2 button this operation excludes all the functions on the instrument panel on the dashboard 2 Move the button 2 to the START position until the engine starts 3 To accelerate or decelerate press and hold button 2 in the START position until the required engine speed is reached then release it this operation will generate acceleration and deceleration effects al...

Page 28: ...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 ...

Page 29: ... YOU OPERATE INTRODUCTION This section of the Operation Manual describes the diesel fuel engine oil and engine coolant specifications and how to replenish them SAFETY PRECAUTIONS Before performing any operations within this section review the Safety section on page 3 ...

Page 30: ...ls must meet certain specifications The biodiesel fuels must meet the minimum specifications for the country in which they are used In Europe biodiesel fuels must comply with the European Standard EN590 2009 EN14214 In the United States biodiesel fuels must comply with the American Standard ASTM D 6751 Grade S15 D7467 Grade B7 S15 Biodiesel should be purchased only from recognized and authorized d...

Page 31: ...0 1 is preferred Total aromatics content should not exceed 35 by volume 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 Low temperature diesel EN 590 specifications distinguish different classes of diesel fuel identifying the characteristics of those best s...

Page 32: ...can be used compliant with specifications ASTM D6210 Type 1 FF provided that the internal engine cooling circuit has been suitably washed beforehand Wash the circuit with fresh water and a specific additive to facilitate removal of any residue before changing the fluid If a concentrated product is used mix it 50 with water It is not permitted to mix different fluids organic and inorganic based as ...

Page 33: ...Sudden Movement Hazard Be sure the boat is in open water away from other boats docks or other obstructions before increasing engine speed Avoid unexpected equipment movement Shift the marine gear into the NEUTRAL position any time the engine is at idle To prevent accidental equipment movement never start the engine in gear Sever Hazard Keep children and pets away while the engine is operating SAFE...

Page 34: ...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 SPECIAL WARNINGS High coolant temperature If high temperature is indicated by the instruments or with an alarm reduce the engine speed and return to port to check the status of the seawater inlet and the cooling circuits ...

Page 35: ... Visually check that the exhaust circuit is not clogged or damaged to prevent hazardous or toxic emissions inside the pipes Failure to comply with these warnings can result in the risk of serious injury and serious damages Battery or alternator charging fault Periodically check the cleanliness condition and correct tensioning of the drive belt WARNING Risk of injury The rotating elements are locat...

Page 36: ...n 10 seconds after entering the password into the display 8 Move the control head handle to the N Neutral position 9 Press the Engine START STOP switch 2 Figure 1 and power on the starter When the engine starts the VC20 display will show the screen with engine conditions Figure 4 NOTE 1 Concerning the control head SEL lamp For Multi Station the SEL lamp will flash and for Single Station the SEL la...

Page 37: ...e indicators on the display and the control head are normal 2 Check for water or oil leakage from the engine 3 Check that exhaust color engine vibrations and sound are normal 4 When there are no problems keep the engine at low speed to send engine oil to all parts of the engine 5 Check that sufficient seawater is discharged from the seawater outlet pipe Operation with inadequate seawater discharge...

Page 38: ... position The engine will remain idling Pulling the handle back further will increase the engine speed Forward Reverse to Reverse Forward Moving the handle quickly and switching from forward reverse to reverse forward will activate the gear shift delay astern delay The engine speed will decrease to idle speed for several seconds Figure 6 ENGINE SPEED LIMIT MODE 1 Move the control head handle to th...

Page 39: ... 3 Are there abnormal vibrations or noise NOTICE Excessive vibration may cause damage to the engine marine gear hull and onboard equipment In addition it causes noticeable passenger and crew discomfort 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 abnor...

Page 40: ... 3 Press the Engine START STOP switch on the switch panel of the selected station to stop the engine 4 Press the Power switch to turn the power OFF CAUTION Do not press the Engine START STOP switch when the engine is stopped The engine will restart Do not turn the Battery switch OFF before turning the Power switch OFF NOTICE Wait 4 seconds or more before turning battery switch off for secure syste...

Page 41: ...l tank Close seacock s If there is a risk of freezing check that the cooling system contains enough coolant See page 28 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 ...

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Page 43: ...rine engine WARNING Welding Hazard Always turn off the battery switch if equipped or disconnect the negative battery cable and the leads to the alternator when welding on the equipment Remove the engine control unit multi pin connector Connect the weld clamp to the component to be welded and as close as possible to the welding point Never connect the weld clamp to the engine or in a manner which w...

Page 44: ...ven death Make sure that all connections are tightened to specifications after repair is made to the exhaust system Failure to comply could result in death or serious injury The Importance of Daily Checks The Periodic Maintenance Schedule assumes that the daily checks are performed on a regular basis Make it a habit to perform daily checks before the start of each operating day Keep a Log of Engin...

Page 45: ...o bolts that are not listed Apply 80 torque when tightened to aluminum alloy When lock adhesive is applied decide separately When seal washer applied torque is 34 5 N m 25 1 3 7 ft lb 8 8 Bolt Diameter x Pitch mm M6x1 0 M8x1 25 M10x1 5 M12x1 75 M14x1 5 M16x1 5 Tightening Torque N m 10 8 1 0 25 5 3 0 18 8 2 2 88 2 10 0 140 0 10 0 230 0 10 0 ft lb 8 0 0 7 18 8 2 2 36 2 3 7 65 1 7 4 103 7 2 170 7 2 T...

Page 46: ...ine performance Ambient temperature 15 C to 40 C 5 F to 104 F Relative humidity 80 or lower The diesel fuel should be ASTM D975 No 1 D S15 No 2 D S15 or equivalent minimum of cetane No 45 The lubricating oil should be API Service Categories CI and CI 4 Be sure to perform inspections as outlined in Maintenance Procedures on page 45 and keep a record of the results Pay particular attention to these ...

Page 47: ...ver comes first Every 300 hours or 1 year whichever comes first Every 600 hours or 1 year whichever comes first Every 900 hours or 1 year whichever comes first Every 1200 hours or 2 years whichever comes first Every 2400 hours or 4 years whichever comes first Every 3000 hours or 5 years whichever comes first Engine oil level check Engine coolant level check Drain the water from the pre filter Chec...

Page 48: ...0 1200 2400 3000 Daily Every 150 hours or monthly whichever comes first Every 300 hours or 1 year whichever comes first Every 600 hours or 1 year whichever comes first Every 900 hours or 1 year whichever comes first Every 1200 hours or 2 years whichever comes first Every 2400 hours or 4 years whichever comes first Every 3000 hours or 5 years whichever comes first Check seawater engine oil heat exc...

Page 49: ...is low remove the filler cap 1 and top up through the filler port on the cylinder head cover ATTENTION After topping up the oil make sure that the level does not exceed the Max notch on the dipstick 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 ...

Page 50: ...emely violent manner with the risk of burns Only open the pressure cap of the coolant tank when the engine is cold Failure to comply with these instructions can result in the risk of serious injury NOTICE General instructions The failure to observe the aforesaid procedure does not guarantee the presence of the correct quantity of coolant in the engine Failure to comply completely or partially with...

Page 51: ...diesel is released 4 Manually close the Drain Valve by screwing it in completely 5 Loosen the Air Bleed Valve 6 Work the manual pump until the fuel comes out of the Air Bleed Valve then close the 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 pu...

Page 52: ...ptions can result in the risk of serious injury Proceed after positioning the batteries on a horizontal surface Flooded lead acid batteries only Figure 3 Visually check that the level of the fluid is between the Min and Max limits If there are no references check that the fluid covers the Lead plates in the elements by approx 5 mm When required only use distilled water to top up the elements whose...

Page 53: ...oration is detected Visually check the state of the battery The terminals must not show signs of deterioration and the body must not be damaged otherwise they should be replaced CLEAN THE AIR FILTER Only proceed with engine off Figure 4 Unlock the clamp 1 then remove the air filter Blow a jet of dehumidified compressed air onto the filtering element working from the inside out maximum pressure 200...

Page 54: ...ndition of oil vapor filter Only proceed with the engine stopped and at a low temperature so as to avoid the risk of burning With a clogged sensor Refer to the indications provided by the sensor and if a clogged status is signaled replace the filter as indicated in this document With no clogged sensor Remove as indicated in the instructions for replacement Check that the filter element shows no si...

Page 55: ...bled when the power is on but engine is not started 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 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...

Page 56: ...ly after having drained the waste oil in order to avoid the risk of burns Place a container under the filter support to collect the used oil Unscrew and remove the filter 1 Carefully clean the surfaces Apply a thin layer of oil on the sealing gasket of the new filters Manually tighten the new filters on the bracket until it comes into contact with the gasket then tighten by 3 4 of a turn Dispose o...

Page 57: ...hten by 3 4 of a turn Loosen the Bleed Screw on the filter mount and pump the pre filter hand pump until the fuel comes out with no air bubbles present Tighten the Bleed Screw and start the engine while pumping the hand pump during the first stages of start up General directions Do not fill the new fuel filter until it has been installed on the support to prevent any damaging impurities from enter...

Page 58: ... pre filter from the mounting bracket 5 Install the new filter element on the mounting bracket 6 Reinstall the Drain Valve and Water Sensor in the filter 7 Connect the electrical connection to the Water Sensor 8 Open the Air Bleed Valve and work the hand priming pump until only fuel comes out 9 Close the Air Bleed Valve WARNING Risk of injury Dispose of consumable materials and the parts in contac...

Page 59: ...y risk of burns Remove the belt cover 1 from the pulley and the belt Figure 12 Check that the belt 1 is not worn soiled with oil or fuel or showing signs of tears If any of these conditions are identified replace the 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 ...

Page 60: ...f the caps is indicated on page 10 After emptying refit the caps in their housings ensuring that the sealing rings are intact Refill the circuit completely as indicated in the table on page 28 Run the engine briefly while observing the coolant level at the filler cap and top up as required Bleed the coolant circuit as follows Leave the engine idling and carefully loosen the screw positioned on the...

Page 61: ...ving placed the filter in its seat CHANGE OIL VAPOR FILTERS Figure 14 Only proceed when the engine is not turning and is at low temperature so as to prevent the risk of burns 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 prev...

Page 62: ...tions The operations indicated above require the use of specific equipment which will guarantee that the result is safe effective and of a good quality 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 completely or partially with these requirements may r...

Page 63: ...NCE 6LT Series Operation Manual 59 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 ...

Page 64: ...WARNING Risk of damage Replace the auxiliary belt if there is any sign of abrasion cracks or tears oil or fuel stains Failure to comply completely or partially with these requirements may result in the risk of serious damage to the engine and may even on occasion invalidate the warranty WARNING Risk of injury When the engine is off but still hot the belt may start to move without warning Wait for ...

Page 65: ... without starting by energizing terminal 50 of the electric starter motor with positive system voltage using a specially arranged conductor 6 Spray the Preservative Oil 1 into the turbocharger inlet while cranking the engine as described above for about 15 seconds 7 Close all of the engine s intake discharge ventilation and bleeding holes with plugs or seal them with adhesive tape 8 Drain the resi...

Page 66: ...n 6 Start the engine and let it idle for at least 5 minutes 7 Check that the indications on the dashboard are plausible and that there are no alarm signals 8 Run the engine until the thermostat opens coolant temperature of 68 C checking for leaks Stop the engine 9 Check fluid levels and top up as needed Remove the warning notices of ENGINE WITHOUT OIL from the engine and instrument panel DIRECTION...

Page 67: ...ill adopt strategies defined as minimum accelerated speeds allowing safe navigation of the boat under emergency conditions ATTENTION The engine s electronic control unit may adopt the safety strategies at any point during navigation when conditions arise which could compromise the integrity of the engine If any of these conditions occur proceed with extreme caution checking that on board personnel...

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Page 69: ... min 1 470 kW 2530 min 1 Installation Flexible mounting Fuel Injection Timing Variable timing Electronic control Fuel Injection Pressure Variable pressure Maximum injection pressure 160 MPa Direction of Rotation Crankshaft Counterclockwise viewed from flywheel side Cooling System Long Life Coolant with heat exchanger Lubrication System Forced lubrication system Cooling Water Capacity coolant 38 L ...

Page 70: ...SPECIFICATIONS 66 6LT Series Operation Manual This Page Intentionally Left Blank ...

Page 71: ...6LT Series Operation Manual 67 6LT Series Operation Manual EPA WARRANTY USA ONLY ...

Page 72: ...parts for such maintenance replacement or repair However the cost of such service or parts and subsequent failures from such service or parts will not be covered under this emission control system warranty Warranty Period The warranty starts on either the date of delivery to the first end user or the date the unit is first leased rented or loaned The warranty period is five 5 years or 1000 hours o...

Page 73: ...l scheduled maintenance Your engine is designed to operate on diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with applicable emission requirements You are responsible for initiating the warranty process You are responsible for presenting your marine engine to an authorized Yanmar dealer or distributor as soon as a problem exists Customer Assistan...

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