OPERATION MANUAL Be sure to read this manuaI for safe and proper operation． Store this manual carefully after use．
Congratulations on your choice of YANMAR product from YANMAR DIESEL ENGINE CO., LTD. This manual describes operation, periodic inspection and maintenance servicing for the ENGINE manufactured by YANMAR DIESEL ENGINE CO., LTD. Please read this manual carefully before use, and operate your engine properly under the optimum conditions, should you have any questions or concerns, please do not hesitate to contact your nearest dealer or distributor.
YANMAR MARINE DIESEL ENGINE MODELS : 6LYA-STP, 6LY2A-STP OPERATION MANUAL Thank you for purchasing the YANMAR Marine Diesel Engine. [INTRODUCTION ] ● This Operation Manual describes the operation, maintenance and inspection of the 6LYA-STP, 6LY2A-STP Yanmar marine diesel engines. ● Read this Operation Manual carefully before operate the engine to ensure that the engine is used correctly and that it stays in the best possible condition. ● Keep this Operation Manual in a convenient place for easy access.
INDEX page No. INTRODUCTION ……………………………………………………………………………………………………1 INDEX ……………………………………………………………………………………………………………………2 1. FOR SAFE OPERATION ………………………………………………………………………………3~6 1.1 Warning Symbols …………………………………………………………………………………………………3 1.2 Safety Precautions ……………………………………………………………………………………………4~5 1.3 Location of product safety Labels ⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯⋯6 2. EXPLANATION OF PRODUCT ……………………………………………………………………7~16 2.1 Use, Driving System etc. …………………………………………………………………………………………7 2.
1. FOR SAFE OPERATION 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.
1.2 Safety Precautions (Observe these instructions for your own safety.) ■ Precautions DANGER 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.
WARNING Alcohol ● Never operate the engine while you are under the influence of alcohol or when you are ill or feel unwell as this results in accidents. ■ Safety DANGER 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. Wash it off immediately with a large quantity of fresh water if you get any on you.
1.3 Location of Product Safety Labels To insure safe operation, warning device labels have been attached. Warning Device Labels, Parts Numbers Their location is shown in the No. Part Code No. diagram below. Keep the labels from becoming dirty ① 128296-07300 or torn and replace them if they are lost or damaged. ② 120324-07240 Also, replace labels when par ts are replaced, ③ 128296-07260 ordering them in the same way as for the parts.
2. Explanation of Product 2.1 Use, Driving System, etc. In the case of engine with marine gear, connect the propeller shaft to the marine gear output shaft. 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. The engine must be installed correctly with safe cooling water and exhaust piping and electrical wiring.
2.2 Engine Specifications 6LY2A-STP Engine model 6LYA-STP Type Vertical water cooled 4-cycle diesel engine No. of clinders 6 Bore × Stroke Displacement mm Fuel stop power at crankshaft kw(hp)/rpm Cont. power at crankshaft. kw(hp)/rpm High idling rpm Low idling rpm 100×110 105.9×110 5.184 272 * (370) / 3300 **264 (359) / 3300 5.
2.3 NAMES OF PARTS Lube oil filter Fresh water tank Turbo charger Fresh water filler cap Inter cooler Lube oil cooler for marine gear Fuel oil filter Fuel oil injection pump Lube oil cooler Marine gear Engine oil filler cap Lube oil filter Fresh water filler cap Fresh water tank Turbo charger Fuel oil filter Dip stick Marine gear Fresh water cooler Starter motor Alternator Sea water pump V-belt 〈Note〉 This illustration shows Yanmar marine gear (Model : KMH6A) when it has been attached.
2.4 Major Servicing Parts Name of Part Function ●Fuel filter Removes dust and water from fuel. Drain the filter periodically, (there is a drain plug at the bottom). The internal element (filter) should be changed periodically. ●Fuel feed pump Feeds fuel to the fuel injection pump. Equipped with mechanical pump attached with the fuel injection pomp. ●Engine oil filler cap Filler port for engine lube oil.
2.5 Control Equipment The control equipment consists of the control panel and remote control handle, which are connected by the wires and cables to the control levers for remote control operation. 2.5.1 Control Panel (Optional) The control panel has the following gauges and alarm devices (optional accessories): No.
● New C-type H L 20 H C 11 9 1 3 4 BUZZER STOP ILLUML ON SET OFF 30 x100/m i n 10 40 0 50 C.W. TEMP L.OILPRESS. 00001 ENGINE HOURS OFF ON START GLOW BATTERY CHARGE C.WATER TEMP CLUTCH OIL.P. DIESEL PREHEAT LUB.OIL FILTER LUB.OIL C.WATER LEVEL PRESS. 8 STOP 7 EXHAUST BOOST 2 6 ● 10 New D-type 5 0 4 1 2 3 3 L 4 B O O ST H L.OILPRESS. BATTERY CHARGE C.WATER TEMP LUB.OIL PRESS. CLUTCH OIL.P. DIESEL PREHEAT BOOST C.
(1) Gauges and Equipment Gauges & Equipment Starter switch Before starting during operation GLOW OFF ON Release your hold when engine STSRT engine is started Functions OFF: The switch key can be inserted or removed. All power is turned off. O N: For engine operation. Gauges and alarm devices are turned on. START: For engine starting. When the key is released after starting, it moves automatically to ON. GLOW: For the air heater (optional) (Note) ●The engine cannot be stopped by the starter switch.
(2) Functions of Alarm Devices (Alarm Buzzer & Lamps) 1) The alarm buzzer sounds when any warning lamp (except the charge lamp) comes on. 2) Warning lamps come on when sensors (switchs) detect an abnormality during engine operation. The warning lamps in the display column of the control panel are off during normal operation, but come on as follows when an abnormality arises: Charge Lamp ① BATTERY CHARGE The lamp comes on when there is a charging failure. The alarm buzzer does not sound.
Function of Alarm Devices Before starting OFF →ON After Starting START →ON On Off Charge Lamp On Off Cooling Water Temperature Off Off Engine Oil Pressure On Off Cooling Water Level Off Off Exhaust On Off Boost Off Off Key Operation Alarm Buzzer Alarm Lamps _ 15 _
2.5.2 Remote Control Handle Use the remote control handle in the steering room for ahead, astern and speed control. ● Operation of Single Lever Remote Control Handle (Option) ① : The marine gear shift lever is in neutral. ② : The marine gear shift lever is in ahead or astern ③ : Engine’ s max. speed position. ②∼③ : Acceleration position Neutral Ahead or Astern Max Speed E M Through out knob when free slottle to marine gear shift lever. Side mount type Remote control handle to engine governor lever.
3. OPERATION 3.1 Fuel Oil, Lube Oil & Cooling Water 3.1.1 Fuel [NOTICE] Use of fuels not recommended in this Operation Manual may cause a decrease in engine performance and cause components to fail. (1) Selection of fuel Use the following diesel fuels for best engine performance: ISO8217 DMA, BS2869 A1 or A2 Fuels equivalent to Japanese Industrial Standard, JIS. No. K2204-2 Cetane fuel number should be 45 or greater (2) Fuel Handling 1) Water and dust in the fuel oil can cause operation failure.
3.1.2 Lube oil [NOTICE] Use of Iube oils not specified in this operation manual may cause the seizure or premature wear of internal parts and shorten the engine’ s life. (1) Selection of Engine Lube Oil AIR TEMPERATURB (3) Handling the Lube Oil F 50 122 40 104 30 86 20 68 10 50 0 5 10 15 20 25 30 35 40 55 32 23 14 5 4 13 22 31 40 67 Multi grade SAE 10W20 Yanmar KMH6A, KMH6A1…SAE Viscosity 30 Follow the instructions for other types of Marine Gear.
(1) Handling of Cooling Water 1) Always use purified soft water or distilled water for the fresh water. Never use dirty water or hard water. Impurities in the fresh water cause scale and rust to build up on the cooling water passage, reducing cooling efficiency and causing the engine to overheat. 2) Choose LLC which will not have any adverse effects on the materials (cast iron, aluminum, copper, etc.) of the engine's fresh water cooling system.
3.2 Before Initial Operation Prepare for initial operation according to the following procedures : 3.2.1 Supplying Fuel and Bleeding Air in the Fuel System. DANGER ●Gasoline will catch fire! Check again before supplying that you are using the proper fuel. ●If any fuel is spilled, clean it off completely. (1) Supplying Fuel 1) Before supplying fuel, flush the fuel tank and the fuel system par ts with clean kerosene or diesel fuel.
3.2.2 Supplying Engine Lube Oil 1) Remove the filler cap and supply the engine lube oil. 2) Supply lube oil up to the upper limit on the oil dipstick. To check the oil level, insert the dipstick in fully. Engine Lube Oil Capacity：All 20.0 (oil pan full 16.4 ) 3) Fasten the filler cap fully. [NOTICE] Never supply too much lube oil. If overfilled, oil may come out from the breather and cause engine trouble.
3.2.3 Supplying lube oil to marine gear (for Yanmar model KMH6A, KMH6A1) 1) Remove the filler cap and supply the lube oil to the marine gear. 2) Supply lube oil up to the upper limit on the oil dipstick. To check the oil level, insert the dipstick in fully. Lube Oil Capacity : Full 4.0 3) Fasten the filter cap fully. 3.2.4 Supplying Cooling Water Supply cooling water according to the following procedures. Be sure to add LLC to the fresh water.
6) Check the rubber hose connecting the subtank with the fresh water tank. If the hose is not water-tight, a lot of coolling water will be consumed. [Fig.10] DANGER If the filler cap is loose, hot steam and water will spout out and you may be burned. 3.2.5 Starting after storage or new engine If the engine has not been operated for a long time, the lube oil in the clearance between moving parts will be lost. If operated in that condition, the engine could be damaged.
3.2.6 Checking and Resupplying Lube Oil and Cooling Water When engine lube oil, marine gear lube oil or fresh water is supplied for the first time or they have to be replaced, conduct trial operation of the engine for about 5 minutes and check the quantity of lube oil and fresh water. The trial engine operation will send the Iube oil and cooling water to the parts, so the lube oil and fresh water levels will fall. check and resupply lube oil and fresh water as necessary.
3.3 How to Operate WARNING ●To prevent exhaust gas poisoning, ensure good ventilation during operation. Install ventilation windows, ports or ventilators in the engine room. ●Never touch or allow your clothes to touch the moving parts of the engine during operation. If the front pulleys, V-belt, propeller shaft, etc. catch your body or clothes, serious injury may result. Check that no tools, cloth, etc. are left on or around the engine.
(5) Checking and Resupplying Cooling Fresh Water Check the fresh water level before operation while the engine is cold. Checking the water level while the engine is hot is dangerous, and the cooling water reading will be misleading due to thermal expansion. Only check and resupply fresh water routinely at the subtank. Do not remove the filler cap of the fresh water tank during operation. 1) Check that cooling fresh water level is in betweer Full and Low mark on the side of the sub-tank.
(7) Checking the Alarm Devices When operating the starter switch, check that the alarm devices work normally. (See 2. 5. 1 (3).) (8) Preparing Fuel, Lube Oil and Cooling Fresh Water in Reserve Prepare sufficient fuel for the day's operation. Always store lube oil and cooling fresh water in reserve (for at least one refill) onboard, to be ready for emergencies. 3.3.
(3) Start up of the engine in cold weather When starting the engine under low temperature conditions (approx.0℃ or lower), use the air heater (optional) to enable easier starting. ● ● Turn the starter key from the OFF position to GLOW. Continue to hold the key in the GLOW position to heat up the air heater for about 15 seconds. Starter key switch GLOW OFF ON START Then, return the starter key to START to start the engine.
3.3.3 Shifting [NOTICE] 3.3.3.1 Single-lever type remote control handle (optional) Do not accelerate or decelerate sharply, overload, etc. for the first 50 hours when using a new engine. Return the control lever to neutral before performing the following operation. (1) Ahead (Forward) Gradually tilt the control handle to "Ahead". Tilting the handle gradually to accelerating side, the clutch is thrown in and the boat sails ahead. (2) Astern (Reverse) Gradually tilt the control handle to "Astern".
How to Race the Engine Repeat a cycle of high speed and low speed operation about 5 times at no load with the clutch (marine gear) in Neutral position. Engine racing removes carbon deposits from the cylinder and the tip of the fuel injection valve. If racing is neglected, the exhaust color may worsen and performance may drop. 3.3.5 Stopping the Engine Stop the engine according to the following procedures: 1) Shift the remote control leve to low engine speed and handle to Neutral position to stop the boat.
3.4 Long Term Storage (1) In cold temperatures or before long term (3 months or more) storage, be sure to drain the water from the seawater cooling system. [NOTICE] If water is left inside, it may freeze and damage parts of the cooling system ( fresh water cooler, lube oil cooler, seawater pump, etc.) 1) Loosen the 6 bolts fixing the side cover of the seawater pump, remove the cover and drain the water from inside. 2) After draining, put the pump's side cover back on.
(5) Oil and grease the exposed area and joints of the remote control cable and the bearings of the remote control handle. (6) Cover the turbocharger, exhaust pipe, etc. with vinyl sheets and seal them to prevent moisture from entering. (7) Drain bilge in the hull bottom completely. (If water leakage is found in the hull and water can enter, the boat must be hauled for repair.) (8) Water-proof the engine room to prevent rain and seawater from entering.
4. Maintenance & Inspection 4.1 General Inspection Rules Conduct Periodic Inspection for Your Safety: The functions of engine components will degenerate and engine performance will fall if periodic inspections are not performed. If the countermeasures of the problems are not taken, you may encounter unexpected troubles while cruising at sea. If the periodic inspections are not performed, consumption of fuel or lube oil may become excessive and exhaust gas and engine noise may increase.
4.2 Periodic Inspection Daily and periodic inspection are important to keep the engine in its best condition. The following is a summary of inspection and servicing items by inspection interval. Periodic inspection intervals should vary depending on the uses, loads, fuels and lube oils used and handling conditions, and are hard to establish definitively. The following should be treated only as a general standard.
Schedule Item Description Every 2000 service hrs. Page Adiustment of injection timing ● 45 Overhaul and check of fuel feed pump ● 45 Fuel injection pump Cylinder head and fuel injection valve Daily Electrical parts Turbo charger Marine gear(Yanmar marine gear) Every 250 service hrs. (or 1 yr.) Every 500 service hrs. (or 2 yrs.) ● Adiustment of injection pressure and atomizing condition (1st time) Adjustment of clearance intake and exhaust valve (1st time) ● Every 1000 service hrs.
4.3 Periodic Inspection Items 4.3.1 Inspection after Initial 50 Hrs. Operation （1）Replacing the Engine Lube Oil and Lube Oil Filter (1st time) During initial operation of the engine, the oil is quickly contaminated due to the initial wear of internal parts. The lube oil must therefore be replaced early. Replace the Iube oil filter, too, at this time. Engine lube oil is convenient to drain before the engine has cooled down.
（2）Replacing Marine gear Lube Oil and Cleaning the Filter (Ist time) During initial operation of the engine, the lube oil is contaminated quickly due to initial wear. The lube oil must be replaced early. Clean the clutch Iube oil filter, too, at this time. ①Remove the filler port cover, insert the drain [Fig.20] oil pump hose to the bottom of the marine gear and pump out the lube oil from inside the Lube oil cooler marine gear.
(3) Inspection of Battery WARNING 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 shortcircuiting and fires. 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 be easily ignited.
(4) Draining the fuel oil filter Fuel oil filter 1) Remove the drain plug at the bottom of fuel oil filter and discharge water and dust collected in the fuel oil filter. 2) After draining bleed air from the fuel system. (For further details, see Sec. 3. 2. 1 (2)) Drain plug Center bolt 4.3.3 Inspection after First 250 Hrs.
①Remove the threaded area and the connecting pivot of the remote control cable from the governor lever. Adjust the cable stroke by adjusting the fastening distance of the threaded area. ②Loosen the setting bolt of the remote control cable clamp bracket and adjust the fixing position of the remote control cable. (However, the adjustment of the remote control cable stroke must be made as in ① above.
⑤Run the engine at load for about 10 minutes to dry the turbocharger and check that engine output has recovered. If the output has not recovered, repeat the above cleaning cycle 3 or 4 times. If the output still has not recovered, consult your Yanmar dealer or distributor. ⑥Clean the pre-cleaner with detergent, dry it and install it to the blower air inlet. Replace the pre-cleaner(filter), if broken. [NOTICE] Do not pour a large quantity of blower cleaning agent or fresh water in at once.
Be sure to close the kingston cock before removing the plug to replace the anticorrosive zinc. < Note > [Fig 29] shows the position of the Yanmar marine gear (Model KMH6A). For detailed information on marine gears other than Yanmar ones, refer to the Marine Gear Operation Manual.
(8) Replacing Cooling Fresh Water Cooling performance drops when cooling water is contaminated with rust and scale. Even if LLC is added, the cooling water must be periodically replaced because the properties of the agent will degenerate. To extract the cooling water, open the cooling water cocks (two positions) as shown in 3.4(2). To resupply cooling water, refer to 3. 2. 4. 4.3.5 Inspection Every 500 Hrs.(or 2 yrs.
1) Cracks and loss of impeller ; flaws or excessive wear of impeller tips and side faces. (Note) The impeller must be replaced periodically (every 2000 hours). 2) Damage to wear plate ④If there is no problem with the inner parts, fit the O-ring to the groove of the joint face and re-install the side cover. If water leaks continuously from the water drain pipe beneath the seawater pump during operation, disassembly and maintenance (replacement of the oil seal) is necessary.
(2) Lapping of Intake/Exhaust Valves Adjustment necessary to maintain proper contact of valves and seats. This maintenance requires specialized knowledge. Consult your Yanmar dealer or distributor. (3) Inspection and Adjustment of Fuel Injection Timing Fuel injection timing must be adjusted to ensure optimal engine performance. This maintenance requires specialized knowledge. Consult your Yanmar dealer or distributor.
5. Troubleshooting Trouble ●Alarm buzzer sounds and alarm lamps go on during operation Probable Cause Measure [NOTICE] Shift to low speed operation immediately, check which lamp has come on and stop the engine for inspection. If no abnormality is identified and there is no problem with operation, return to port at your lowest speed and request repairs. ○Eng. L.O. Press. Warning Lamp goes on. Engine L.O. insufficient; L.O. filter clogged. L.O. level check, resupply, replace Replace L.O.
Trouble ○Charge lamp does not go out during operation Probable Cause Measure V-belt broken or loose Reference Replace V-belt; adjust tension Check fluid level, specific gravity; replace. Ask for repairs. 4.3.5(1) No fuel Improper fuel Fuel injection faulty. Compression leaks from intake/exhaust valve. Resupply fuel; bleed air. Use recommended fuel. Ask for repairs. 3.2.1(1) 3.1.1 Neutral safety switch engaged Battery charging insufficient.
_ 48 _ COOLING SEA WATER INLET COOLING SEA WATER PUMP WATER TEMP, SENDER (OPTIONAL) THERMOSTAT HOT WATER HEATER RETURN COOLING FRESH WATER PUMP WATER TEMP, SWITCH HOT WATER HEATER RETURM SAFETY YALVE FUEL OIL OVERFLOW FUEL OIL FILTER OIL PUMP FUEL FEED PUMP FUEL OIL INLET P P P MAIN BEARING CAMSHAFT BEARING P From F.O.
Charge Eng. Oil P. C.W. Temp. Exhaust C.W.
YB Charge Eng. Oil P. C.W. Temp. Exhaust C.W. Level Boost Diesel Preheater Fuel emp. YB Eng. oil p. meter 30 AC 17 G1 G2 P1 P2 AR GLOW 〇 〇 〇 〇 OFF 〇 〇 〇 ON 〇 〇 〇 〇 START 〇 〇 〇 〇 〇 Starter Switch Details of coupler C-C RB GW BW GY BR B Details of coupler A-A YB GB G GR WB YR Y WR YW WL WG B RB LB O YG 3R U3W 3L Eng. oil p C.W. Temp. Exhaust C.W. Level Boost Diesel Preheater Fuel emp.
GLOW OFF ON START Charge Eng. Oil P. C.W. Temp. Exhaust C.W. Level Boost Diesel Preheater Fuel emp. ＋− U ＋−U YB Eng. oil p. meter Boost meter 30 AC 17 G1 G2 P1 P2 AR 〇 〇 〇 〇 〇 〇 〇 〇 〇 〇 〇 〇 〇 〇 〇 〇 Starter Switch Details of coupler C-C RB GW BW GY BR B Details of coupler A-A YB GB G GR WB YR Y WR YW WL WG B RB LB O YG 3R 3W 3L Eng.oil p C.W. Temp Exhaust C.W.
WARRANTY SERVICE Owner Satisfaction Your satisfaction and good will are important to your dealer and to us. Normally, any problems conceming the product will be handled by our dealer's service department. If 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 be quickly resolved at that level.
OVERSEAS OPERATIONS DIVISION 1-32, CHAYAMACHI, KITA-KU, OSAKA 530-8311, JAPAN TEL : 81- 6-6376-6411 FAX : 81- 6-6377-1242 YANMAR DIESEL AMERICA CORP. 951 CORPORATE GROVE DRIVE, BUFFALO GROVE, IL 60089-4508, U.S.A. TEL : 1-847-541-1900 FAX : 1-847-541-2161 YANMAR EUROPE B.V. BRUGPLEIN 11, 1332 BS ALMERE-DE VAART, THE NETHERLANDS P. O. BOX 30112, 1303 TEL : 31-36-5493200 FAX : 31-36-5493209 YANMAR ASIA (SINGAPORE ) CORPORATION PTE LTD. 4 TUAS LANE.
