OPERATION MANUAL

MARINE PROPULSION ENGINE

6AYEM
for IM02

6AYEM-GT
6AYEM-ET

YANMAR
 YANMAR
MARINE DIESEL ENGINE
OPERATION MANUAL

Thank you for purchasing a YANMAR Marine Diesel Engine.

[INTRODUCTION]
• This Operation Manual describes the operation, maintenance and inspection of
the YANMAR marine diesel engine.
• Read this Operation Manual carefully before operating 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.
• If this Operation Manual is lost or damaged, order a new one from your
authorized YANMAR 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 such differences, please
contact your authorized YANMAR dealer or distributor.
• The specifications and components (instrument panel, fuel tank, etc.) described
in this manual may differ from the ones installed on your vessel.
Please refer to the manual provided by the manufacturer of these components.

r 'I

California
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the state of
California to cause cancer, birth
defects, and other reproductive harm.
\. ~

Please review and comply with the applicable laws and regulations of the
international export control regimes at the territory or country where the product
and manual are intended to be imported and used.

MODEL 6AYEM-GT, 6AYEM-ET

OPERATION MANUAL
CODE 0AAYE-EN00S0

All Rights R()s()rv()d, Copyright. YAN MAR CO., LTD.

CONTENTS
FOR YOUR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Symbols ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Labe~ ................................................................................................ 5
Precautions for Lifting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PRODUCT OVERVIEW ...................................................... 9

Engine Features ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9
Specifications... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1O
Location of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Monitoring and Control Systems ............................................................... 12

FUEL OIL, LUBRICATING OIL AND COOLANT .................... . 19

Fuel ................................................................................................... 19
Lubricating Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Coolant ............................................................................................. 20

OPERATING ..................................................................... 21
Checking before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cranking (No-load Running) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Warm-up ............................................................................................. 29
Operating the Engine and Marine Gear ...................................................... 31
Notice while Running with Load ............................................................... 32
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

PERIODIC MAINTENANCE ................................................ 35

Periodic Maintenance Schedule ............................................................... 35
Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

LONG-TERM STORAGE ...................................................... 46

TROUBLESHOOTING ......................................................... 47
When You Encounter an Error ............................................................... 47
Checking the Warning Indication on the LCD Monitor ................................. 47
DTC Code and Error Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Emergency Operation Using the Backup Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
 FOR YOUR SAFETY - 1

FOR YOUR SAFETY

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.

Safety Symbols
These are the warning signs used in this manual and on the product.

This safety alert symbol appears with most safety statements. It means attention, become alert, your

A 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

A.CAUTION 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.

Others
This manual contains supplementary explanations regarding operation.

IMPORTANT indicates information that is important for the correct usage and
- IMPORTANT - operation of the equipment.
2- FOR YOUR SAFETY

Safety Precautions
Safety precautions for operation

Burns from steam

• Never remove the filler cap from the coolant tank while the engine is still hot.
Steam and hot air will spurt out and seriously burn you.
Ii 1 After engine stop, wait until the water temperature drops. Wrap a cloth around the filler cap
and slowly loosen the cap.
• After inspection, tighten the filler cap firmly.
If the cap is not secure, steam or hot air can spurt out during operation and seriously burn
you.

Ventilation of the battery area

• Make sure that the area around the battery is well-ventilated and that no flammable materials
are near.
The battery emits hydrogen gas during operation and charging. The gas can catch fire.

Fires from oil ignition

• Be sure to use the correct type of fuel oil. Always double-check before fueling.
The wrong fuel oils (e.g. gasoline) can cause a fire.
• Be sure to stop the engine before fueling.
If you spill fuel oil, wipe the spillage carefully.
• Keep oil and other inflammable materials away from the engine.
They can catch fire.

Exhaust gas poisoning

• Never cover or block the windows, air vents, fans or other ventilation devices in the engine
room. Always maintain good ventilation in the engine room during operation.
Breathing exhaust gas is dangerous to your health.

Moving parts
• Keep your hands, other body parts and clothing away from moving parts (e.g. the front drive
shaft, V-belt or propeller shaft). You will get caught and injured.
• Never operate the engine without the covers on the moving parts.
• Before engine start, check that you removed all tools and cloths from the area near the
engine.

Alcohol and drugs

• Never operate the engine while you are under the influence of alcohol or drugs. Never oper-
ate the engine when you feel ill or unwell.
 FOR YOUR SAFETY - 3

&CAUTION
Burns
• Be careful of burns. The entire engine is very hot during and after operation.
• Keep your hands, other body parts and clothing away from the exhaust manifold, exhaust
pipes, turbocharger, air cooler and engine body.

Safety precautions for maintenance

Burns from steam

• Never remove the filler cap from the coolant tank while the engine is still hot.
Steam and hot air will spurt out and seriously burn you.
After engine stop, wait until the water temperature drops. Wrap a cloth around the filler cap
and slowly loosen the cap.
• After inspection, tighten the filler cap firmly.
If the cap is not secure, steam or hot air can spurt out during operation and seriously burn
you.

Fires from oil ignition

• Be sure to use the correct type of fuel oil. Always double-check before fueling.
The wrong fuel oils (e.g. gasoline) can cause a fire.
• Be sure to stop the engine before fueling.
If you spill fuel oil, wipe the spillage carefully.
• Keep oil and other inflammable materials away from the engine.
They can catch fire.

Fires from electric short-circuits

• Always turn off the battery switch or detach the earth cable(-) before you inspect the electri-
cal system.
If you cause a short-circuit, a fire can occur.

Moving parts
• Stop the engine before you inspect it. If you have no choice but to inspect the engine while it
operates, keep your hands, other body parts and clothing away from rotating parts.
You will get caught and injured.

Exhaust gas poisoning

• Never cover or block the windows, air vents, fans or other ventilation devices in the engine
room. Always maintain good ventilation in the engine room during operation.
Breathing exhaust gas is dangerous to your health.
4- FOR YOUR SAFETY

Side cover opening

• Do not open the side cover when the engine is hot. The new air intrusion may lead to an
explosion .

.A.CAUTION
Battery fluid
• Be very careful not to expose your skin or eyes to the battery electrolyte.
The electrolyte is a strong acid and can cause inflammations.
If you come in contact with the battery fluid, wash it off immediately with a lot of freshwater.

Burns

d • Be careful of burns. The entire engine is very hot during and after operation.
• Keep your hands, other body parts and clothing away from the exhaust manifold, exhaust
pipes, turbocharger, air cooler and engine body.

No modification
To keep the engine in good condition, the engine ECU has been sealed to control the engine speed limit and the fuel
injection quantity. If a seal is removed, the sliding and moving parts of the engine will suffer from increased wear.
Engine performance will deteriorate and service life may shorten significantly. And the engine will be damaged and
broken. Therefore, do not remove any seals. If the seal is removed, no warranty will be given even during the
warranty period.

Regulation on NOx
Laws on maritime pollution and hazard prevention regulate the replacement of certain parts. The laws require that a
record and the signature of personnel who replaces these parts is kept. All inspections and maintenance must be
performed by our professional service technicians with the necessary expertise and skills.

Waste disposal
• Never dispose of waste oil, such as lubricating oil, by dumping it into a sewer, river, lake or ocean
waters.
• Do not spill waste oil into ocean waters. Use a container to collect waste oil from the engine.
• Comply with relevant laws and/or regulations for the disposal of hazardous materials such lubricat-
ing oil, fuel, filters or batteries.
 FOR YOUR SAFETY - 5

Labels
For safe operation, the affixed position of the labels is indicated.
Read the remarks of the labels carefully to attempt prevention of the accident.
Also, if you need to replace a part that has a label affixed to it, make sure you order the new part and label at the
same time.
If the labels are damaged or fallen, order them from your authorized YAN MAR dealer or distributor.

■ Operation side

1 2 3

•liii~~l:.:l;I;~-\' •:; :1~1!1Jlt

t.i:L'1!1'~L', •i!l!iiti<IIX~
ti:\ L,~lt.!:~T7.iri!l::ti.ilb ~), Do not lift the engine
•Never remove the cap while the
engine is still hot. •Hot water vertically or diagonally.
may spurt out and burn you.
128296-07260 Please check no damage to
or 3 l'l ont~s.
3.When cooi,~g water temperature reaci,es
heat the lifter before lifting

engine.

A .
WARNING
~
5

A -~
WARNING
C1
L:I::..

• i!l!~$1;1:, if-::>t=L'l='l'--\'>!li~
No. Part No. •W:Jt~, 1 0 m',JJ,;l;IJlltt>&:L'c'l'~L'o
Alh.t..L,'l!(t::~L',
· >.r:fit,t Ql!i,t,.t><ii •J aa't. 1 128296-07260 • ffilwl'.J\•:J:•Jll§Wii\\tLil%•Ja:t"
• Exposed moving parts 2 129198-07350 • Don't open 1 Omin. after stop
• Can cause injury 1411116--07210 3 148660-07770 • Can cause injury by explosion
4 141616-07210 141816-07200

5 141616-07200
069621-00X0l
6- FOR YOUR SAFETY

■ Non-operation side

1 2 3
IRubber-impelleritype water pumpl
1.Don't run the pump under
A CAUTION
;t ~ VISCUS DAMPAR MAINTENANCE
dry condition because im-
peller is damaged.
2.Drain the pump of water
removing pump cover or
drain plug. while turning
tire engine. after the en-
gine stopped in cold sea-
son. because the pump is iiim&l:'i:A
broken far freezing. • <!:b-l> .!:-l"lt 1:.'f:T-l>
r.l<nb<il!,<Jlle"t".

5
A~ WARNING
1!5-

Do not lift the engine

vertically or diagonally.

Please check no damage to

No. Part No. • i!l!fi<,j,l;l;, -tf-:itcL'i='f.-l"ffil!:
the lifter before lifting 1 135665-07210 J..;11.t.i:L'"l!( tc<!P.
engine. 2 141616-07220 • 'Tfi'l:"t"-l>ltJ:;t,.t><ilo•Jlle"t".
3 148619-28990 • Exposed moving parts
· Can cause injury 141616-07210
148660-07770 4 148660-07770
5 141616-07210 069618 -00X02
 FOR YOUR SAFETY - 7

Precautions for Lifting the Engine

The engine can cause serious injury when it falls during lifting. Obey the below instructions to prevent accidents
during lifting.

• Make sure that the engine is lifted by qualified persons.

• Before lifting, make sure that the engine lifting bracket and mounting bolt have no damage and are in
good shape. If you find a fault, stop immediately and contact your authorized YAN MAR dealer or distribu-
tor.
• Select lifting tools (e.g. wire rope and shackle) that are appropriate for heavy loads.
• Select the wire rope length so that the engine does not tilt during lifting.
• Before lifting, examine the lifting tools and make sure that they have no damage and are in good shape.
• Protect the parts of the engine or driven equipment that touch the wire rope with protective material.
• The tension of the wire rope changes depending on the lifting angle. Make sure that the angle is within
60°.
• If you use a marine gear that is not listed in this operation manual, separate the marine gear from the
engine, and lift the marine gear and engine separately.
• During lifting and moving the engine, do not go under the engine or near the engine.
• Do not lift the engine vertically or diagonally. Please check no damage to the lifter before lifting engine.

Less than 60 degrees

069119-00EN00

For the mass, refer to Specifications in the Operation Manual.

8- FOR YOUR SAFETY

Engine Nameplates
Periodic inspection and maintenance are important to help you enjoy your engine.
Your serial number is required at the time of requesting an engine maintenance or ordering a part.
Confirm it beforehand.

■ Location of engine nameplate:

It is affixed under the No. 4 cylinder side cover of the cylinder block on the fuel injection pump side.

0
Model
Gear Model
Continuous power kW kW/ min· 1
- - - - - - - - -

~~~~~~ft ~~
- - - - - - - - -

Fue I stop power kW

ENG. No.
 PRODUCT OVERVIEW - 9

PRODUCT OVERVIEW

Engine Features
This engine features a common rail type fuel injection system and an electronic control system. This electronically
controlled engine can control the fuel injection and speed of the engine to keep the engine condition and the exhaust
gas clean in the best condition.

■ Common rail type fuel injection system

The fuel pressurized by the high pressure pump fills the accumulator (common rail), and the solenoid valve electron-
ically controlled by the engine controller/ECU finely injects the fuel with high pressure under control.
The engine controller receives the operating state (such as speed or load) of the engine from each engine sensor
signal to calculate the best fuel injection timing/pressure/amount, and electronically controls the solenoid valve of the
injector.

■ Operating device: Electronic control system

This device is used by connecting the engine, reduction reversing gear, etc. using the wire harness, and for operat-
ing the same.
10 - PRODUCT OVERVIEW

Specifications
Engine model Unit 6AYEM-GT 6AYEM-ET

Type - Vertical, water-cooled, 4-cycle diesel engine

Combustion system - Direct injection

No. of cylinders - 6

Bore x Stroke mm 155 X 180

Displacement L 20.379

Rating - s L M Continuous

Rated output kW 749 737

670(911) 610 (829) 555 (755)
(flywheel output) (PS) (1018) (1002)

Rated engine speed min- 1 2000 2000 1938 1900 1840

Crankshaft rotation direction - Counterclockwise (viewed from the flywheel side)

Coolant seawater 2 system cooling

Cooling system -
(Engine/Oil cooler: Coolant, other cooler: Sea water)

Engine - 65
Coolant
capacity -
Reservoir tank 3

Lubricating system - Forced lubrication with gear pump

Standard oil pan: 91

Engine -
Lubricating Shallow oil pan: 53
oil capacity
Marine gear - Refer to marine gear manual

Turbocharger type - Exhaust gas turbocharger (with Air cooler)

Starting system V-kW Electric starting/Air starting (option)

Engine dry mass

kg 2418
(without marine gear)
 PRODUCT OVERVIEW - 11

Location of Components
■ Operating side

Engine stop
switch

Air cooler

Alternator

Side cover

Fuel fllteri.----

Electric fuel priming - - - -

pump
Fuel high pressure _ ____
----a Oil filler cap
pump

Dipstick
069619-0lENOl

■ Non-operating side

Coolant filter cap

Exhaust manifold

Turbocharger Coolant tank

(Heat exchanger)

Water pump
Starter (coolant)

Engine oil
bypass filter

Engine oil filter

12 - PRODUCT OVERVIEW

Monitoring and Control Systems

■ LCD monitor
• LCD monitor is a liquid crystal panel that can be set to the operator's seat apart from the engine.
• At normal state, the LCD monitor shows the gauge panel for monitoring the operation status.
• If some kind of error occur to the engine, a warning message will appear on the monitor along with the warning buzzer.
• Consult your YAN MAR dealer or distributor about warnings.

1 monitor single engine

y
© y
© y
© y

iE D D m e o m 06987':i-0lEN0l 061929 -ooxoo

D Engine speed D Shift position

Indicates the engine speed with a pointer. Indicates the gear shift position.
f) Engine load F (Forward), N (Neutral), R (Reverse)

Indicates the engine load with percent. UiJ Fuel tank level
D Running hours Does not show unless it is connected.

Displays the number of total running hours. mRudder position

D Coolant temperature Does not show unless it is connected.

Indicates the temperature of the fresh water with a iE Propeller speed

pointer. Does not show.

El Oil pressure
• Warning buzzer and warning sound stop-
Indicates the lubricating oil pressure with a pointer.
ping switch
l'l) Boost pressure The buzzer starts when the warning message is indi-
Indicates the pressure of the air that is pumped by the cated.
turbocharger to the combustion room with a pointer.
• Mode switch button
D Fuel rate
On the side of the screen is a push button for switching
Displays the engine's fuel consumption amount.
between low lighting mode for night operation and list
Iii Battery voltage mode for showing the engine data.
Displays the voltage of the starting battery.
 PRODUCT OVERVIEW - 13

1 monitor dual-engine

6 D E f.i m

©] y
©] f~ 11~0~1, ~~ r., ,{ (;) ~) y
©] \1~,~) 3~!) 8 \\~~.~7 3~)) y
©] >~~~=~~,~~~~
~✓. ~·,
~o~")
✓
4
\V····,J11 .,r :~ltV
. '"')) . ":J y 4

~~/'< ~~~~--------]
COOLANT " · - ~
:----•~A~o
,,r OIL 25.8
~}}____/
·!25:8 i COOLANT , ce::r
••• OIL
TEMP Boos·, PRESSUR,. V '~v TEMP BOOST PRESSURE

e
I

\
\

061929 -ooxoo

m e om
D Engine speed (port and starboard)
fJ Running hours (port and starboard)
D Coolant temperature (port and star-
board)
D Oil pressure (port and starboard)
El Boost pressure (port and starboard)
[l) Battery voltage (port and starboard)
D Shift position (port and starboard)
D Fuel tank level
Does not show unless it is connected.

D Rudder position
Does not show unless it is connected.

• Warning buzzer and warning sound stop-

ping switch

• Mode switch button

14 - PRODUCT OVERVIEW

■ Monitoring screen
• Monitoring screen has main display and list display.
• The main display are DAY mode and NIGHT mode. The DAY mode and NIGHT mode shows the same screen but
becomes darker at NIGHT mode.
• The list display is initially set to monitor the items shown in the main display by data/item/gauge.
• By push buttons on the left and right while the LCD monitor is being displayed, the screen switches between Main
display (DAY mode)/Main display (NIGHT mode)/List display.

Main screen (DAY mode)

Main screen (NIGHT mode)

Button

List screen

0@ifF==,.=::"=" ~I- ==~-e=e~,,c=e~Se=e~e-0==:5=,=,=::=~.,=""'7).,......,.

'~"--------·-·1]~! 1.:.1~
••••
l:::::===CM~j;:;:.~~;'.:~~~~~~~;:;:::::~===;e:::j:::j~'.
~'°~''="=="'Be~He~½~ita~,=='.~'
:
~'="
:

® --~-======-- e
,,__=--- =-- -= -------=-< -----=a<
069037-00EN0l
 PRODUCT OVERVIEW - 15

■ Switch panel
The switch panel is equipped in the steering room and
the engine room start panel (Optional).
The switching is done by a push button.

0 Power switch
Engine electric system turns ON, and the engine can
be started.

f) START/STOP switch
This switch is for starting and stopping the engine.
Press once for starting the engine, and press again for
stopping.

D Emergency stop switch

Press this button to stop the engine at emergency.

- IMPORTANT------~
• Start the engine with the clutch handle at N (Neutral)
position.
• Do not press the power switch and the START/
STOP switch while operating.
• Do not press the emergency stop switch unless it is
an emergency.

■ Engine room ECU box

The ECU box is set in the engine room apart from the
engine. In the box, a drive ECU, DC/DC convertor, etc.
are assembled, and display panel and lamp are pro-
vided on the door.

0 Display panel YANMAII

Normally, the display panel shows the gauge indicating
the engine operating state. If any error occur to the
engine, the warning is indicated and the buzzer starts.

f) After-run lamp
This will not show while operating. When the power
switch is turned OFF, it will turn on after blinking for 10 C
Llf.T_l_;fl__ fl!-!'l_J
f)
seconds.

- IMPORTANT------~
0697J0-00EN02
If the optional engine room start panel is set, the dis-
play panel will not be provided on the ECU box. Only
the lamp will.
16 - PRODUCT OVERVIEW

■ Engine room start panel (Option)

• The start panel is a panel used for starting the engine and is set in the engine room apart from the engine.
The marine gear clutch cannot be operated.
• When operating the start panel, the clutch handle of the remote control head in the steering room should be in
Neutral.
• The start panel includes Select switch, Switch panel, Display panel and Engine speed dial.

r:o r:=;:=::=~1

□ [(
~
I f)
'

01--- ()~_.!/
D 8
i----SELE_C_T___7
I e

~
YANMAR 069558--00EN0J

0 SELECT switch D Display panel

Press this to switch to the engine side for starting the
engine in the engine room. When it is switched, the
lamp turns green.
To operate the engine from the steering room after
starting in the engine room, press the SEL switch
(change operating place) on the remote control head
in the steering room to switch to the steering room
side.
Normally, this part displays the gauge indicating the
engine operation state, and when anything abnormal
happens to the engine, a warning message will show
up along with the buzzer.
D ENGINE SPEED dial
This dial is for operating the engine speed only.
The speed increases as it is turned right.

f) Switch panel
The same switch panel as the steering room is
equipped.
You can start and stop the engine from the engine
room.

- IMPORTANT------=
The engine can also be stopped by using the stop but-
ton equipped to the engine.
 PRODUCT OVERVIEW - 17

■ Remote control head

You can adjust the engine speed and operate the clutch switch (forward and reverse) of the reduction reversing gear
with one handle.
The handle controls the direction of the boat (ahead or astern) and also acts as an accelerator by increasing engine
speed as the lever is pushed further in FORWARD or REVERSE directions.
The remote control head has function button and lamp.

069863-00EN00

0 NEUTRAL lamp
"NEUTRAL lamp" will be on when the remote control head handle is in N (Neutral).

£1 NTRL (Warm up mode/Shift disconnect mode) switch

The engine speed can be controlled with the clutch in neutral state.
Press this when you only need to operate the warm-up or the engine speed.

&CAUTION
Sudden Moving
If you operate the handle without pressing this "NTRL switch", the marine gear's clutch will be engaged and
the vessel will start moving.

B SEL/Select switch
When operating the engine at multi stations, you will need to select the side (Position) you will be operating. In order
to switch the operating location, press "SEL switch", and determine the operating position. When you are finished
selecting, the lamp above the switch will be turned on.

If there are more than two positions to operate, "SEL switch" will be blinking. Unless you select the operating
positions, the engine cannot be operated.

D SYNC/Synchronizing switch (Only for dual-engine control head)

lfthere are dual-engine, to synchronize the two engine's speeds, press "SYNC switch".
18 - PRODUCT OVERVIEW

■ Backup panel
If by any chance, for example, an error occurs to the remote controller head, and the engine throttle or the clutch
cannot be controlled, the backup panel is there to be used in emergency.

- IMPORTANT------=
Do not use unless it is an emergency.

D Power switch
Press this switch ON to turn on power.

f) Lamp
After pressing the power switch ON, this lamp will on.

D Engine START/STOP switch

Press this switch to either start or stop the engine.

D Shift switch D e ooxoo

This switch is the clutch switch of YXH-240-7 marine

gear.
A cover usually is on this switch.
(FWD: Forward, NTRL: Neutral, REV: Reverse)

El SUB THROTTLE volume

This volume is the engine speed adjuster.
(Right turn: High speed, Left turn: Low speed)

A.CAUTION
When you operate the vessel using the backup
panel, please be very careful of not only the moves
of the vessels around you but also yourself.
 FUEL OIL, LUBRICATING OIL AND COOLANT - 19

FUEL OIL, LUBRICATING OIL AND COOLANT

Fuel
■ Diesel fuel selection
Use clean Marine Gas Oil (Diesel Fuel) for the fuel oil.
• Diesel fuel should comply with the following guidelines. The fuel specifications need to comply with each national
standard or international standards.

Quality critical equivalent fuel oil ASTM D975 No. 2D equivalent

EN590
BS-2869 Class A 1 or A2
Property critical value Sulfur content below 0.5 % by volume
Diesel index Cetane No. 45 or higher
Viscosity at 50 °C 3 - 8 mm-2/s

· ·~--
• Only use the recommended fuel to obtain the best engine performance and to keep the durability of the engine, as
well as to comply with the emission regulations.
• The fuel injection system consists of precision parts and for that reason, do not use fuel to which water and dust
are mixed in. If such fuel is used, it causes trouble.
Consequently, pay attention to water or dust when supplying fuel.
Beside these, carry out draining and maintenance servicing of the fuel filter as mentioned in the Periodic Mainte-
nance Schedule.

Lubricating Oil
■ Selection
Use an engine oil that meets or exceeds the following guidelines.
• Oil grade: A.P.I. CF
• SAE viscosity: 15W-40
• T.B.N [mgKOH/g]: 9 - 15

• Do not mix lubricating oils of different types or brands. Mixing may cause lubricating performance to decrease,
reducing the engine's life.
• YAN MAR does not recommend the use of engine oil "additives".
• When supplying engine oil, pay attention to water or dust. Clean around the filler port before filling.
• Make sure to carry out changing of the engine oil and maintenance servicing of the oil filter as mentioned in the
Periodic Maintenance Schedule.
20 - FUEL OIL, LUBRICATING OIL AND COOLANT

Coolant
■ Coolant selection
Use clean coolant (tap water) for the coolant.
Use the water having the properties shown in the following table.

Water quality for coolant

pH 298K (25 °C) 6.5 - 8.0
Total hardness (CaCO 3 ) :s: 100 ppm
M alkalinity :s: 100 ppm
Ammonium ion (NH 4+) concentration :s: 0.05 ppm
Chloride ion (Cl-) concentration :s: 100 ppm
Sulfate ion (SOi-) concentration :s: 100 ppm
Evaporation residue :s: 400 ppm

■ Long Life Coolant (LLC) mixture selection

Always add Long Life Coolant (LLC) to the tap water. This mixture serves as the coolant.
YANMAR recommends the following Long Life Coolant (LLC):
• TEXACO LONG LIFE COOLANT/standard and premixed
Product Code 7997 and 7998
• HAVOLINE EXTENDED LIFE ANTIFREEZE/COOLANT
Product Code 7994
or equivalent to the above LLC.

Choose LLC which will not have any adverse effects on the materials (cast iron, aluminum, copper, etc.) used in the
engine's cooling system, if different from the above.

Without this mixture, scale or rust is generated inside the parts of the coolant system, thus deteriorating cooling per-
formance. In winter, never neglect to us LLC in order to prevent freezing.
If LLC use is neglected, the coolant freezes and expands inside the engine, resulting in breakage of parts in the cool-
ant system. The mixing ratio of LLC depends on the temperature. Be careful in using the mixing ratio specified by
the manufacturer.

• Excess LLC deteriorates cooling performance.

A thin mixture which does not provide protection sufficient for the lowest temperature will freeze and damage the
coolant system.
• Never mix different types (brands) of LLC, chemical reactions may make the LLC useless and engine trouble
could result.
 OPERATING - 21

OPERATING

Checking before Starting

Do these checks before engine start.

Visual inspection of the engine

Check the following and make sure that there are no
defects. If you find a defect, do not start the engine.
Consult yourYANMAR dealer or distributor.
• Check for oil leaks from the lubricating oil system.
• Check for fuel oil leaks from the fuel system.
• Check for water leaks (seawater and coolant) from
the cooling water system.
• Check for gas leaks from the exhaust pipe.
• Check parts for damage and chippings.
• Check for loose or missing bolts.
• Check for loose or missing bolts.

Checking and refilling fuel oil

• Drain water of the fuel tank. Fuel gauge
• Check the fuel level of the tank. Keeping the plenty
fuel oil level is important. If necessary, refill with a
recommended fuel oil.
• Sufficiently refill fuel oil to avoid running out of fuel
oil during operation.
• Fill the tank with clean fuel that is free of water and
OOENOO
dirt.
• Open the fuel cock (or valve).
22 - OPERATING

Bleeding the fuel oil system

Bleed air in the fuel system and obey the following pro-
cedure when you fill fuel oil to the fuel tank for the first
time, perform maintenance (such as replacing the fuel
filter) of the fuel system, after the fuel oil has run out,
and when there is a failure at startup.
If the equipped fuel filter comes with a change lever,
the position of the change lever is normal/looking up
(uses two filters).
1. Check the fuel oil level in the fuel tank and open the
fuel cock (or valve).

2. Loosen the air vent plug on the top of the fuel filter.

3. Fill the fuel oil with the fuel priming pump.

1- The knob on the priming pump rises when you
turn it counterclockwise.
2- Repeat pushing the knob continuously by
hand.

4. Fuel oil with air bubbles comes out of the air vent Knob
plug hole of the fuel filter.

5. When fuel oil without air bubbles comes out of the 061701-00EN00

air vent plug hole, tighten the air vent plug.

6. After you discharged air, screw the priming knob

clockwise tightly while pressing.
tr~I ,,w fJ Tighten

7.At start operation, repeat restarting until the engine

starts running.
',.,'.,,.,..

lllll'lllm ~
Rm
r-1'1
• If you keep "START/STOP" on for 15 seconds, lit\\r/ \\\( \0\ , ,
\ (
1\9-~.·. ~0~1 c\
r='~;® I
the starter will stop.
\ ~ / '21 n,,,,,. /
>-..
l~p
P.Yr .
,,.-;$,
~
;___,,,-"'
11·1,I
1 I~
1l1 Ii~ 061701-0lENOO
• If the engine does not start at once, wait for more
than 15 seconds and then start again.
 OPERATING - 23

Filling lubricating oil

Keeping the correct oil level is important.
Obey the following procedures when you fill the engine I ,,, ,
., , ,---- cf _/
lubricating oil. r,, /
fr'
_,..- _.. I

1. Remove the oil filler cap.

2. Fill the recommended oil to the upper level mark
on the dipstick while checking the level with the
dipstick.

Engine lubricating oil capacity

91 L
(Standard oil pan)
013813-02EN04
3. Install the oil filler cap.

lllll'lllm
• Be sure to stop the engine before refilling.
• When checking the oil level, insert the dipstick
fully.
• Do not overfill with oil, as this may cause oil to
be sprayed out from the breather and damage
the engine.

Filling and checking coolant

1. Be sure to check the condition of tighten all the
coolant drain cocks before filling coolant.
2. Remove the filler cap of the coolant tank.
3. Fill the coolant tank with coolant up the filler neck.
4. Fill the reservoir tank with coolant up to the upper
level (FULL) mark.

11111:lllEl
• Always fill with clean coolant.
• Always use coolant mixed with LLC.

5. Tighten the each filler cap securely.

6. Check to be sure that the joint of the overflow pipe
between the reservoir tank and coolant tank are ----, _j

securely tightened.
FULL
'r======::.t¢ Full

LOW

----- _j '¢Low
001687-02E
24 - OPERATING

Checking seawater line

1. Be sure to check the condition of tighten all the
seawater drain cocks and joints of water hoses.
2. Open the seawater cock (or valve).

Checking battery switch

1. Be sure to check the condition of tighten all the
connecting terminals and harnesses.
2. Turn ON the battery switch before engine start.

Keep the battery switch in the ON position when

operating the engine.

Rechecking after starting

When a new engine is operated for first time, the oil
level of the oil pan will drop because the engine oil is
circulated to the oil cooler, oil filter, etc.
Therefore, stop the engine after operating for test run-
ning.
Wait for about 5 minutes more and then check the
engine oil and coolant level, and refill to the upper level
if necessary.
 OPERATING - 25

Cranking (No-load Running)

Before starting the engine for the first time, or starting
the engine after a long period of time, cranking should
be done beforehand.
Cranking should be done under safe condition.

1. Make sure that the battery switch is turned OFF.

2. While holding the locking tab of the engine harness Electric fuel priming pump

connector, disconnect the connector of the electric

fuel priming pump.

- IMPORTANT-----=-
Connector
lf engine cranking is performed while the connector
is still connected, an alarm may activate when the
107902- 00EN0l

engine starts.

3. Make sure that the fuel valve and sea cock (valve)
Switch panel
are open, and then turn ON the battery switch.
4. Turn OFF the all load used at front power take off.
5. Move the remote control head handle to N/Neutral.
6. Start cranking with the switch panel in the steering i2;J
room or the engine room start panel (optional).
1- Turn ON "Power switch" on the switch panel. @@~i~C)i~;I_ __,__ Emergency stop switch
2- Press "SELECT switch" (Green lamp turns on),
. . Power switch
to execute cranking on the engine side (engine ~-,!j !

room start panel only). QJ7627-00EN05

3- First press "Emergency stop switch" on the

switch panel, and then press "START/STOP
switch" to start turning the starter. The cranking
time should be within 5 seconds, and check for
ENGINE SPEED dial Switch panel
abnormal noise.
y ~
4- If you release "START/STOP switch", the
starter will stop. @--1- START/STOP
" switch
@

- IMPORTANT------= ~ - - Emergency
~ 1 I stop switch
When you start cranking with the engine room start (Q)--- Power switch
panel (Optional), "ENGINE SPEED dial" is Low 1
/2
speed. SELECT switch
26 - OPERATING

7. After the engine has stopped, press "Emergency

stop switch" to turn it OFF.

- IMPORTANT------=
"Emergency stop switch" will stay ON once it is
pressed. Press it again to turn it OFF.

8. Turn OFF the power switch of the switch panel,

Electric fuel priming pump
and turn OFF the battery switch.
9. Insert the connector of the electric fuel priming
1/
pump into the engine harness connector until it
clicks into place completely.

Connector
- IMPORTANT------=
Securely connect the connectors. 00EN02
 OPERATING - 27

Starting the Engine

Starting the engine at the steering room
1. Turn ON the battery switch. Switch panel
2. Turn ON "Power switch" on the switch panel. The
power switch lamp turns on.
3. Wait until the gauge and warning panel displays
the gauge (the pointer and the data). The pointer
should be pointing "O".
4. Make sure that the screen isn't displaying waning
messages (alarms).
5. Press "SEL switch" on the remote control head,
@:---:,-----'c--- Power switch

and make sure that "SEL lamp" turns on.

- IMPORTANT------=
SEL switch
The remote control head cannot be operated unless
"SEL lamp" is on.
When the lamp is blinking at operating position,
press "SEL switch" to turn on the lamp.

6. The remote control head handle is N/Neutral.

"NEUTRAL lamp" turns on.

069306-00EN0S

- IMPORTANT------=
When starting the engine, the remote control head
handle is in N/Neutral position.

7. Press "START/STOP switch" on the switch panel

to start the engine.
8. Make sure that the pointers and other information
are displayed on the monitor screen, and not the
alarm.
069?06-00EN06

• If you keep "START/STOP switch" on for 15 sec-

onds, the starter will stop.
• If the engine does not start at once, wait for more
(2j
than 15 seconds and then start again.
@:
~
©)
037627-01EN02
28 - OPERATING

Starting at the engine room (Option)

1. Turn ON the battery switch. ENGINE SPEED dial
Switch panel
2. Turn ON "Power switch" on the switch panel of the Display pa
engine room start panel. "Power switch" will light V l
up. "Power switch" will be kept on while operating.
3. Press "SELECT switch" (green lamp will turn on), ~c~.
l-0-!I ~ ~8 ~
(©-- START/STOP
@
switch

and start from the engine room. #

OiiiaJ
'-~-
@
Power switch
- IMPORTANT-----=- j

A
The remote control head handle is in N (Neutral).
SELECT switch

4. Wait until the display panel shows the gauges (The

pointer should be at 0), and make sure that the
warning (alarm) is not showing in the screen.
5. "ENGINE SPEED dial" is in Low speed.
6. Press "START/STOP switch" on the switch panel,
and start the engine.
7. Make sure that the pointers and other information
are displayed in the gauge display panel screen,
not the alarm.

lllll'llllrE
• If you keep "START/STOP switch" on for 15 sec-
onds, the starter will stop.
• If the engine does not start at once, wait for more
than 15 seconds and then start again.
 OPERATING - 29

Warm-up
Please warm up the engine for about 5 minutes after
starting. Warm the engine and make sure the lubricat-
ing oil goes though each part. If you find any error
while warming up, or a warning shows up, please con-
tact your authorized YAN MAR dealer or distributor.

1. The remote control head handle is in N/Neutral.

Press "NTRL switch" on the remote control head.
"NEUTRAL lamp" turns on.

£CAUTION
When you warm-up, press "NTRL switch" on
the remote control head not to gear shift.

2. While operating, go through the following check list

to make sure there are no errors occurring.
• The gauges are displayed correctly.
• No warnings are showing.
• Cooling water is sufficiently discharged from the 069306-00ENOl

seawater discharge port.

• No fuel, lubricating oil, cooling water, gas, or air
is bleeding from any engine part.
• Exhaust gas color, vibration, operating noise is
normal.
3. After the warm-up is done, press "NTRL switch" to
release.

If you put load without warming up, or when the

discharge amount of seawater is not enough, the
engine becomes overheated, and may cause the
internal parts to burn. If the seawater amount is low,
immediately stop the engine, and check the strainer
clogging or anything you can to avoid the worst.
30 - OPERATING

Warm-up at engine room start panel

(Lciw)=====:J I ~~....
(Option)
1. Warm up with "ENGINE SPEED dial" in the Low 0--+ENGINE

speed position: Minimum speed.

2. Check up while warm-up and make sure nothing is eaE =□I sll.D=.l~.ial
abnormal.
3. After warm-up, switch to operation in steering room.
o
SELECT
l__~
- IMPORTANT------- 062999--00EN0l

After checking the engine operation in the engine

room, when you start operating from the steering
room, press "SEL switch" on the remote control
head.
 OPERATING - 31

Operating the Engine and Marine Gear

■ Switching clutches (Forward, Reverse)
Move the remote control head handle to the F/Forward
side or the R/Reverse side until it stops. Forward idle Neutral
The engine speed stays the same. To shift from F to R, F Shift N
place the handle at N/Neutral position, and then move.

■ Engine speed adjustment (Accelerate

and decelerate)
If you move the remote control head handle to F/For-
ward or R/Reverse, speed remains at idle, but when
you further move the handle completely, the engine
rotation rises and the speed becomes faster. The
speed will slow down by putting the handle back in the
original place.

• A new engine should not be operated roughly for the

first 50 hours such as sudden acceleration or over-
loading. It may cause breakage and shorten the
engine's life.
• Please avoid sudden steering. Slowly operate with
little power. If you forcibly operate, the remote con-
trol head may get damaged.
• The clutch switching operation must surely be done.
It cannot be done in an incorrect position (insufficient
position).
32 - OPERATING

Notice while Running with Load

While running the engine, pay attention to the following.
If a problem occurs during operation, try to find the cause. If the cause cannot be found and the vessel is able to
continue operation, return to port at a low speed. Consult your authorized YANMAR dealer or distributor after return.

■ First running
Do not operate new engines at full load during the first 50 hours except for short periods.

■ Caution to lack of fuel amount

■ Cooling water (seawater)

Make sure that water is coming out from the cooling water (seawater) outlet.
When water is coming out intermittently or in small volume, check for the following.
• Is air trapped in the cooling system?
• Is the cooling seawater pump impeller faulty?
• Is the cooling seawater pipe or the sea cock clogged?

■ Color of exhaust gas

Black smoke is a sign that the engine is overloaded. Such operation will shorten the life of the intake and exhaust
valves, piston rings, cylinder liners, turbocharger and particularly fuel injection nozzles. Avoid continuing operation if
black smoke is being emitted.

■ Water leakage, oil leakage and other operational conditions

Always check for the following conditions: water leaks, oil leaks, gas leaks, loose fasteners, abnormal noise, abnor-
mal temperature, low oil pressure and vibration.

■ Alarm devices
When the buzzer sounds during engine running, at first check which alarm lamp is on, immediately set the engine
speed to low speed and stop the engine, and then try to find the cause.

■ Long time operation at low speed

When the engine is operated for more than 4 hours at low speed, set the shift handle to the N/Neutral position, and
increase and decrease the engine speed without load for several times to discharge residue from cylinders every 4
hours of operation.

■ Do not turn OFF the battery switch. Do not spark the battery cable
 OPERATING - 33

Stopping the Engine

■ Stopping the engine (normally)
To stop the engine under normal conditions, press
"START/STOP switch" on the switch panel.

1. Move the remote control head handle to N/Neutral. I

2. Keep the handle to N/Neutral and perform cool- j ~;!' 0

down operation at the idle speed for at least 5 min- II II

I, i~-
utes. 11I
I
'/
I

1\I

-00EN04

Be sure to perform cool-down operation under no

load and at idle speed before stopping the engine. Switch panel
If you suddenly stop the engine without performing
cool-down operation, the engine temperature
increases quickly. This causes deterioration of the
lubricating oil and seizure of moving parts, which
results in engine damage.

3. After performing cool-down operation, press

"START/STOP switch" on the switch panel to stop
the engine.

- IMPORTANT------= Backup panel

When stopping the engine under normal
conditions, do not press "Emergency stop switch".

4. After confirming that the engine has stopped, press

"Power switch" on the switch panel to turn off the
0
power. 037636-0lXOO

The lamp of the backup panel flashes for approxi-

mately 1O seconds and then remains lit.
The lamp of the engine room ECU box also YANMAII
remains lit after flashing.
5. After the lamp on the backup panel has stopped
flashing, turn the Battery switch to OFF.
6. Close the fuel cock (valve) and the sea cock
(valve).

0697J0-00EN0J
34 - OPERATING

• Engine's stop switch

/
The engine is equipped with "Stop switch". '
If you press the switch, the engine will stop.

- IMPORTANT------=
While "Stop switch" is depressed (and not released),
,~<-
y
'~

-~~
/
_,:;

the engine cannot be started.

After stopping the engine by pressing "Stop switch",
~-rn---Ii
~

release "Stop switch" by turning it in the direction of the /' ~'/ 0)~
arrow (to the right). M1l \\
,c: \ \\

\1\\\

■ Engine emergency stop

To perform an emergency stop, press "Emergency
stop switch" on the switch panel.
1. lfyou press "Emergency stop switch" on the switch
panel, the engine will stop. Switch panel
2. The emergency stop screen is displayed on the
instrument/alarm panel.
3. Press "Power switch" on the switch panel to turn
the power OFF. 12:J
4. Wait at least 10 seconds, and then turn the battery
/@S:'c-c'---,-- Emergency stop switch
switch OFF. Then, perform any necessary inspec- \
"'.,.. .Y
;

tions or repairs.
5. When starting the engine after an emergency stop,
always make sure to release the emergency stop
by pressing "Emergency stop switch".
"Emergency stop switch" is ON when depressed.
If it is not released, the engine cannot be started.

- IMPORTANT------=
• Do not press "Emergency stop switch" except in the
case of an emergency.
• An emergency stop can also be performed using the
engine room start panel (optional). To do so, press
"Emergency stop switch" on the switch panel.
• "Emergency stop switch" is ON when depressed.
 PERIODIC MAINTENANCE - 35

PERIODIC MAINTENANCE

Periodic Maintenance Schedule

• Periodical maintenance is an important factor in keeping the engine in the best condition. In accordance with oper-
ating hours given in the following maintenance schedule, perform periodic maintenance.
• When the parts are disassembled for checking and/or servicing, reassemble them properly.
• Please contact your authorized YANMAR dealer or distributor to inspect your engine or to replace any parts if you will.
• Consult your authorized YAN MAR dealers or distributor about scheduling the engine overhaul.

O: Check 0: Replace •: Consult your authorized YANMAR dealer or distributor.

Service period
Item Every Every Every Every Every Remarks
Daily
50 hours 250 hours 500 hours 6 months year
Check fuel level and refill 0
E 0
-gj Drain fuel tank deposit and water
(When replenished)
Ui'
"lii Drain fuel-water separator deposit and water 0
:::;
LI.. Replace fuel filter and fuel/water separator Every 1000
0
element hours
Check oil pressure 0
Check oil level and refill (oil pan) 0
0
E Replace oil filter 0
Q) (1st time)
iii
Ui' 0
C Clean by-pass filter 0
0 (1st time)
~ Clean oil cooler •
~
:::; 0
...J
Standard oil pan 0
Replace oil (1st time)
(oil pan) 0 Every 300
Shallow oil pan 0
(1st time) hours
Check coolant temperature 0
~ Check coolant level 0
iii
Ui' Change coolant 0
"E
0
ro Clean coolant system •
8
Cl)
Check and clean thermostat •
~ Check water leakage from water pump 0
0
0
Replace if found
0
Replace mechanical seal • water leakage
....
Q) Check cooling seawater discharging condition 0
rti
Replace seawater pump impeller 0
~ E
Q)
/Jl
Cl) >,
<I)
iii Check and replace zinc IHeat exchanger 0 0
.!:
0
/Jl anodes IAir cooler 0 0
0
0
0.
Clean seawater system •
E
..c :::;

=
.!:2> 0.
~ Replace pump In the event of a failure, or after 20000 hours
~ ~ <I)
a.
36 - PERIODIC MAINTENANCE

O: Check 0: Replace •: Consult your authorized YANMAR dealer or distributor.

Service period
Item Every Every Every Every Every Remarks
Daily
50 hours 250 hours 500 hours 6 months year

li3 -0
Check and adjust valve clearance •
(1st time) • Every 1500
hours
E! (ti
=
>- .c
0
Q)
Check valve rotator, stem seal, valve spring •
Check oil feeding condition of rocker arm •
- 00
Q)
:::, Q) Replace injector In the event of a failure, or after 20000 hours
u. :1;
I
.:.::~
C
l!! .c
0
(ti

IJ)
Measure and adjust deflection •
0 Q)
.... Clean pre-filter and washing blower 0
........
.0 Ol
:::, m Replace pre-filter 0
F TI
Check air/gas leakage 0
Clean air cooler •
Re-tighten hose clips 0
0
(Fuel, lubricating oil, coolant, breather and air line) (1st time)
Check rubber hoses
0
(Fuel, lubricating oil, coolant, breather and air line)
Check battery electrolyte level and specific
0
Q) gravity
0
·;;: Check battery terminals 0
Q)
-0
0
·;:: 0
Check alternator V-belt tension 0 0
0 (1st time)
Q)
w Replace electric devices
In the event of a failure, or after 20000 hours
{ECU, sensors, harness, etc.)
0
·;::
Check looseness of bolts and nuts 0
Q)

x
w
Check water/oil/gas leakage at various parts 0

Note: Periodic maintenance of the marine gear shall be referred to the manual of your own marine gear.
 PERIODIC MAINTENANCE - 37

Periodic Maintenance Procedures

Fuel system

■ Fuel level check

IService period Daily

Refill as required.

■ Fuel tank deposit draining

Open the drain cock on the tank to drain out sediment
and water at the tank bottom.

IService period Daily

■ Fuel/water separator draining

Drain water from the fuel/water separator.

IService period Every 50 hours

■ Replacing fuel filter

IService period Every 1000 hours

1. Remove the filter with the filter wrench. (Turn to the I,I
I'
-~,,
?,~
;u
,, ~~
_,,~
left.) ~ /

2. Before installing the filter, carefully wipe the instal-

(§) ::~
lation side and apply fuel oil to the packing surface.
'
3. Tighten the fuel oil filter fully by hand, and then use
a filter wrench to further tighten the filter. (Turn to
the right.) ,<
~
4. After replacing the element, be sure to bleed air l

. !; / , \ \ < ~ r
from the fuel system. Ji, U@ i\QA , f'Vo 1/
1 I
I \I \
\).
_,/;//?'--:<A,;: ,,) _;::;:::;
,~Q,,~~ ~,,
1\ i/ / /;?,.:,, ~Q)::,....... .,._. . ., ( ~ 061794-00X00
38 - PERIODIC MAINTENANCE

Lubricating oil system

■ Oil level checking

Check the oil level with the dipstick. Oil level must be
maintained between the upper and lower level marks
on the dipstick. Add the recommended oil up to the
upper level mark, if necessary.

IService period Daily (prior to operation)

■ Replacing oil filter

1. Remove the filter with the filter wrench. (Turn to the
left.)
2. Before installing the filter, carefully wipe the instal-
lation side and apply lubricating oil to the packing
surface.
3. Tighten the lubricating oil filter fully by hand, and
then use a filter wrench to further tighten the filter.
(Turn to the right.)
4. Check for oil leakage during operation.

1st time 50 hours 014350-00X00

Service
2nd time and
period Every 500 hours
after

■ Engine oil change

Wait for about one to two hours after stopping the
engine, connect the end of the rotary pump rubber
hose to the oil drain port, and drain oil. Fill the oil pan
with recommended oil.

1st time 50 hours

Standard
Service Every 500 hours
2nd time oil pan
period
and after Shallow
Every 300 hours
oil pan
0000S6-01X0l
 PERIODIC MAINTENANCE - 39

■ Cleaning of lubricating oil bypass filter

The lubricating oil system is equipped with a lubricat-
ing oil bypass filter.

Stop the engine before cleaning the bypass filter.

Do not disassemble the bypass filter while the engine
is running.

Disassembly and cleaning

Service 1st time 50 hours

period 2nd time and after Every 250 hours
'
8 Cap nut
• Disassembly 0-ring-------<!)
1 Thrust
Disassemble and clean the lubricating oil bypass filter collar
Spring
according to the following procedures.
Cover
Insulator
1. Loosen the cap nut and then remove the cover. assembly
2. Loosen the nut and remove the rotor body. Nut
3. Loosen the lock nut and remove the rotor cover, Rotor bod Lock
then remove the insulator and spring. Nozzle --e--...--r i nut
I
4. Remove the sludge inside the rotor with a spatula. "" ___ -:,,;; Rotor

llllllrlllia
0-ring

,u-0-nng
______ cover

Completely remove the sludge. Otherwise,

residual sludge may cause an unbalance in
rotation, resulting in damage to the bearing of the
spindle shaft.
Spindle shaft ,:~:=:~ l)
¾
~~,

~
5. Check for clogging of the nozzle and clean the
nozzle a brass wire brush.
6. Check each part and the 0-rings. If any damage or
excessive wear is found, replace the part.

•Assembly
Assemble the filter in the sequence reverse to disas-
sembly while observing the following precautions.
1. Install the insulator spring into the rotor body and
cover the rotor body with the rotor cover.

llllllrlllia
Ensure that the fitting of rotor and rotor cover is
secure. When the fitting is not aligned, the rotor
speed becomes unbalanced and it may damage
the equipment.
40 - PERIODIC MAINTENANCE

2. Tighten the rotor cover to the rotor body with a lock

nut.

ILock nut tightening torque I Hand-tighten

3. Insert the rotor to the spindle shaft and tighten the

nut by hand-tighten

INut tightening torque Hand-tighten

4. Cover the cover, install the thrust collar (upper),

and tighten the cap nut.

Bypass filter (Part No. 148620-35310) (E/#: to 7071)

9.8 N•m (1.0 kgf•m) Or,

Tightening
after the tighten by hand fully,
torque of
use a spanner for M12 and
cap nut
tighten for 1 to 1-1 /4 turns.

Bypass filter (Part No. 148620-35311) (E/#: from 7072)

16 ± 2 N•m (1.6 ± 0.2 kgf•m) Or,

Tightening
after the cap nut is attached,
torque of
use a spanner for M12 and
cap nut
tighten for 1 to 1-1 /4 turns.

lllll'lllllE
Avoid overtightening the nut and cap nut. When
the cap nut is overtightened, the tightening power
is lost during loosening at the next time and it may
cause the spindle shaft to loosen.

5. While operating the filter, make sure oil does not

leak from connected sections. Also, make sure the
filter is not vibrating abnormally.
 PERIODIC MAINTENANCE - 41

Cooling water system

■ Coolant system
• Coolant level checking
Check the coolant level in the reservoir tank before
starting the engine in the cold condition.
The level should be between "FULL" and "LOW' level
mark. Add coolant if necessary.

Never remove the filler cap when the engine is hot

(above 60 °C).

IService period Daily

•Water pump (coolant) leakage checking

Leakage of coolant may cause serious problems, such
as seizure of the engine, as the volume of coolant
decreases.
If there is water leakage, consult your authorized
YAN MAR dealer or distributor.

IService period Daily

• Changing coolant

IService period Every year

• Be sure to replace the coolant at the specified time.

• Be sure to follow the correct mixture ratio for Long
Life Coolant (LLC). (Refer to [Coolant])
42 - PERIODIC MAINTENANCE

■ Seawater system
Heat exchanger
• Discharging seawater
From time to time during operation, check if water is
coming out of the seawater outlet pipe. If water comes
out intermittently or its volume is low, stop the engine
immediately and check for the cause.

IService period Daily (during operation)

• Checking and replacing zinc anodes

Remove the zinc anode and scrape or remove with a
wire brush the coating on the zincs. If more than 50 %
of the zinc is corroded away, it should be replaced with Air cooler
new zinc.
Zinc anodes are built into the heat exchanger and air
cooler.

Service Checking Every 250 hours

period Replacement Every 500 hours

013300-0lX

• Replacing seawater pump impeller

1. Remove the pump cover and pull out the impeller.
Check the impeller, the wear plate and cover.
2. If the impeller, wear plate and cover are exces-
sively damaged, replace them with new ones.
3. When reassembling the pump, apply grease to the
fitting area of the pump shaft and impeller, both
end faces of the impeller and the tip of impeller
blades.
000728-0lE

4. When installing the impeller, position blades of the

impeller as shown in the illustration at right.

IService period Every year

000984-0lE
 PERIODIC MAINTENANCE - 43

Turbocharger

■ Cleaning pre-filter
A pre-filter removes contaminations in the air and
keeps the engine output in good condition.

1. Wash the pre-filter with a neutral detergent.

2. Wash the pre-filter with tap water, dry it sufficiently,
and install.

Service Washing Every 250 hours

period Replacement Every year

■ Washing blower
If the turbocharger blower is contaminated, the blower 037121-02X00

speed decreases and the boost pressure drops, caus-

ing the engine output to fall. Wash the blower, if the
boost pressure drops (approx. 10 % pressure drop
compared with normal condition).

1. Prepare the blower wash fluid, freshwater, and oiler.

2. Remove the pre-filter from the intake silencer, and
remove the water filler plug.
3. During the load operation, fill 50 cc of the blower
wash fluid slowly from the water filler in approx. 10
seconds.
4. Approx. 3 minutes after filling the blower wash
fluid, fill 50 cc of the freshwater from the water filler
in approx. 10 seconds.
5. Continue the load operation for approx. 10 minutes
to dry and check the output recovery.
6. Repeat the above washing operation for 3 to 4
times, if the performance is not recovered. Consult
your authorized YAN MAR dealer or distributor for
repair.

When the boost pressure drops by

Service
10 % in comparison with the trial
period
run. Or every 250 hours.

Do not fill a large amount of the wash fluid and fresh-

water at once. It may result in a water hammer acci-
dent.
44 - PERIODIC MAINTENANCE

Electrical parts

■ The alternator drive belt tension

Put load in a right angle on the center of the belt span.
The span length is 223 mm, adjust until the deflection
is 12 mm at 100 N load.

• Adjusting the V-belt

1. Loosen the lock bolt (1) of the alternator. Adjust the
tension of the V-belt with the adjuster nut (2).
2. After you adjust, tighten the adjuster nut (2) and
the lock bolt (1) of the alternator.

3. Replace the V-belt if it is damaged.

After 50
1st time
hours
Checking
Service 2nd time Every 500
period and after hours
Replacing
Every year
V-belt

■ Inspection of the battery

IInterval Every 250 hours (or every month) Lower Upper

TI ~
r·------_j
• Battery fluid level i
Check the battery fluid level periodically because bat-
i
i

tery electrolyte (fluid) decreases as charging. If the

fluid is near the lower level, refill with commercial distil-
lated water until the upper level.
In hot conditions (e.g. during summer), check the fluid
level earlier than specified. This is because the battery
033952-0lEN00
fluid evaporates faster.

• Battery fluid specific gravity

If the engine rotation does not rise and the engine <j----
does not start, measure the specific gravity of the bat-
tery fluid.

Battery fluid standard

1.28 (at 20 °C)
specific gravity

Recharge the battery if the measured specific gravity

value is lower than the specified value: 1.22.
If the specific gravity does not increase, replace the
battery.
 PERIODIC MAINTENANCE - 45

Piping

■ Re-tighten the rubber hose clips

(fuel oil, lubricating oil, cooling water,
air, mist)
Check the joints and check for any oil, water, air, or gas
leaks. Then, re-tighten the hose clips.

1st time After 50 hours

Inspection
2nd time
interval Every 6 months
and after

■ Check rubber hoses (fuel oil, lubricat-

ing oil, cooling water, air, mist)
Check the rubber hoses that appears worm or has
cracks.

IInspection interval Every year

46 - LONG-TERM STORAGE

LONG-TERM STORAGE

In storing the engine for a long time and re-starting the engine after long- term storage, the following treatments are
required, please request check and maintenance after consulting with your authorized YAN MAR dealer or distribu-
tor.

■ The method of storing for a long time

• For the items that periodic maintenance is approaching, do the check and maintenance before storing for a long
time.
• In cold conditions, drain the cooling water for prevention of a freeze.
• Loosen the V-belt.
• Remove the battery cable from the minus terminal side. Charge the battery at least once a month to prevent voltage
drop by self-discharge.
• Carefully wipe off dust and oily dirt and apply a rust inhibitor or clean oil to the outside of the engine.
• Provide protection covering for the exhaust pipe, intake port, and electric parts to protect against humidity.
• Close the fuel cock (valve) and sea cock (valve).

■ Draining water from the cooling water channel

Be sure to drain all cooling water from both the seawater and coolant channel.
It is not necessary to drain the coolant when Long Life Coolant is mixed.
• Drain the seawater from the drain tap of the seawater channel or a seawater pump is opened.
• When Long Life Coolant is not being used for the coolant, the drain tap of the coolant channel is opened then
drain the coolant.

If it does not drain water, the water left inside the engine will be frozen and the parts of the cooling water channel will
be damaged.

■ Restarting the engine after long-term storage

• When the engine is stored for more than a year without operating it, the engine inspection and maintenance are
required.
• Take off the rust inhibitor and do the same start preparation as for the initial start of a new engine.
• Check the impeller of a seawater pump for damage and apply white Vaseline.
• Check the V-belt for damage and replace with a new one if needed. Adjust the V-belt tension.
• Install the battery cable from the plus terminal side.
• When the coolant is drained with where the drain cock opened, let water flow for washing the coolant channel.
Then close the water drain cock and fill the coolant.
We recommend addition of Long Life Coolant to the coolant.
• In order to spread lubricating oil over each part before starting the engine, make sure that cranking is certainly car-
ried out.
• Do an engine warm-up after starting the engine. Make sure that the lubricating oil is coming out from the rocker
arm.
• Check the level of the lubricating oil and coolant after engine warm-up operation.
Refill the amount whichever is decreased.
 TROUBLESHOOTING - 47

TROUBLESHOOTING

When You Encounter an Error

This engine is electronic controlled. If any error occurs to this engine and the alert sound goes off along with the
warning indication on the gauge/warning panel, immediately decelerate the engine, and put the clutch to N "Neutral".
Check the situation and the error detail. Then stop the engine, and refer to P48 [OTC Code and Error Message] for
checkup and solution.
If you are not sure, please tell the following information to your authorized YAN MAR dealer or distributor.

• Engine number
• Detail of the error and how it occurred
• Warning indication/message on the gauge/warning panel, OTC code, error name
• Engine speed (Change)
• Hour meter display time
• Exhaust gas color
• Whether there are abnormal sounds or vibration.
• Other

Checking the Warning Indication on the LCD Monitor

1. Notifications, warnings, and alarms will be shown
as the Pop-up window on LCD monitor.
2. Press the button on the side of DETAIL showing
the pop-up. All of the warnings will be shown on
the alarm list.

~I .c g
~ OTC Co rna
@)b=======

069070-00EN02
48 - TROUBLESHOOTING

DTC Code and Error Message

Failsafe actions
Level 1: Reduce engine speed to 1500 min-1 or less
Level 2: Reduce engine speed to 1100 min-1 or less
Level 3: Reduce engine speed to low idle

Failsafe action
With
DTC SPN FMI DTC description Warn- Level Level Level ENG
FFD
ing 1 2 3 stop
P1626 522744 4 ACTUATOR DRIVE1 SHORT CIRCUIT X

P1633 522994 4 ACTUATOR DRIVE2 SHORT CIRCUIT X

P1467 523471 6 ACTUATOR DRIVE3 SHORT CIRCUIT X

P1004 523016 5 ACCESSORY RELAY OPEN CIRCUIT X

P160C 158 0 BATTERY VOLTAGE TOO HIGH X

P1638 158 1 BATTERY VOLTAGE TOO LOW X

P1568 167 1 CHARGING SYSTEM ERROR X

P0118 110 3 COOLANT TEMP SENSOR H RANGE X

P0117 110 4 COOLANT TEMP SENSOR L RANGE X

P2560 111 1 COOLANT LEVEL LOW X

U0292 522596 9 CAN COMMUNICATION ERROR TSC1 X

U1304 459726 9 CAN COMMUNICATION ERROR Y-PM1 X

P1613 522585 12 ECU ERROR CY146 SPI COMMUNICATION X X

P0601 630 12 EEPROM ERROR MEMORY DELETION X

P160E 522576 12 EEPROM ERROR MEMORY READ X

P160F 522578 12 EEPROM ERROR MEMORY WRITE X

P0341 522401 2 CAM SENSOR IRREGULAR SIGNAL X

P0342 522401 5 CAM SENSOR NO SIGNAL X

P1341 522401 7 CAM SENSOR SIGNAL ANGLE OFFSET X

P0336 522400 2 CRANK SENSOR IRREGULAR SIGNAL X X

P0337 522400 5 CRANK SENSOR NO SIGNAL X X

P018D 94 3 FUEL PRESS SENSOR H RANGE X

P018C 94 4 FUEL PRESS SENSOR L RANGE X

P0183 174 3 FUEL TEMP SENSOR H RANGE X

P0182 174 4 FUEL TEMP SENSOR L RANGE X

P1146 2797 6 INJECTOR BANK1 SHORT CIRCUIT X X

P1149 2798 6 INJECTOR BANK2 SHORT CIRCUIT X X

P0611 523492 12 INJECTOR DRIVER1 IC ERROR X X

P1023 523493 12 INJECTOR DRIVER2 IC ERROR X X

P0201 651 5 INJECTOR1 OPEN CIRCUIT X X

P0204 654 5 INJECTOR4 OPEN CIRCUIT X X

P0202 652 5 INJECTOR2 OPEN CIRCUIT X X

P0206 656 5 INJECTOR6 OPEN CIRCUIT X X

P0203 653 5 INJECTOR3 OPEN CIRCUIT X X

P0205 655 5 INJECTORS OPEN CIRCUIT X X

P1262 651 3 INJECTOR1 SHORT CIRCUIT X X

P1271 654 3 INJECTOR4 SHORT CIRCUIT X X

P1265 652 3 INJECTOR2 SHORT CIRCUIT X X

P1277 656 3 INJECTOR6 SHORT CIRCUIT X X

P1268 653 3 INJECTOR3 SHORT CIRCUIT X X

P1274 655 3 INJECTORS SHORT CIRCUIT X X

P0262 651 6 INJECTOR1 COIL SHORT CIRCUIT X X

P0271 654 6 INJECTOR4 COIL SHORT CIRCUIT X X

P0265 652 6 INJECTOR2 COIL SHORT CIRCUIT X X

P0277 656 6 INJECTOR6 COIL SHORT CIRCUIT X X

P0268 653 6 INJECTOR3 COIL SHORT CIRCUIT X X

 TROUBLESHOOTING - 49

Failsafe action
With
DTC SPN FMI DTC description Warn- Level Level Level ENG
FFD
ing 1 2 3 stop
P0274 655 6 INJECTORS COIL SHORT CIRCUIT X X

P0627 633 5 FUEL PUMP OPEN CIRCUIT X X

P1645 522572 11 FUEL PUMP OVER LOAD X X

P0629 633 3 FUEL PUMP SHORT CIRCUIT VB-H X X

P1642 633 6 FUEL PUMP SHORT CIRCUIT GND-H X X

P1641 522571 3 FUEL PUMP SHORT CIRCUIT VB-L X X

P1643 522571 6 FUEL PUMP SHORT CIRCUIT GND-L X X

P1469 523473 12 ECU ERROR AD CONVERTER 1 X X

P1470 523474 12 ECU ERROR AD CONVERTER 2 X X

P1471 523475 12 ECU ERROR EXT MONITOR IC & CPU 1 X X

P1472 523476 12 ECU ERROR EXT MONITOR IC & CPU 2 X X

P1473 523477 12 ECU ERROR ROM X X

P1474 523478 12 ECU ERROR SHUTOFF PATH 1 X X

P1475 523479 12 ECU ERROR SHUTOFF PATH 2 X X

P1476 523480 12 ECU ERROR SHUTOFF PATH 3 X X

P1477 523481 12 ECU ERROR SHUTOFF PATH 4 X X

P1478 523482 12 ECU ERROR SHUTOFF PATH 5 X X

P1479 523483 12 ECU ERROR SHUTOFF PATH 6 X X

P1480 523484 12 ECU ERROR SHUTOFF PATH 7 X X

P1481 523485 12 ECU ERROR SHUTOFF PATH 8 X X

P1482 523486 12 ECU ERROR SHUTOFF PATH 9 X X

P1483 523487 12 ECU ERROR SHUTOFF PATH 10 X X

P1484 523488 0 ECU ERROR ENGINE SPEED RECOGNITION X X

P0219 190 0 X ENGINE OVER SPEED X X

P1608 522588 12 SUPPLY VOLTAGE H RANGE X X

P1617 522589 12 SUPPLY VOLTAGE L RANGE X X

P068A 1485 2 MAIN RELAY EARLY OPEN X

P068B 1485 7 MAIN RELAY STUCK X

P0523 100 3 LUBE OIL PRESS SENSOR H RANGE X

P0522 523552 4 LUBE OIL PRESS SENSOR L RANGE X

P0238 102 3 BOOST PRESS SENSOR H RANGE X

P0237 102 4 BOOST PRESS SENSOR L RANGE X

P1666 523469 0 PLV OPEN EXCEED SPECIFIED TIMES X X

P000F 157 16 PLV OPEN X X

P1667 523470 0 PLV OPEN EXCEED SPECIFIED HOURS X X

P0094 157 18 RAIL PRESS DEVIATION ERROR L X X

P0093 157 15 X RAIL PRESS DEVIATION ERROR H X X

P0088 157 0 X RAIL PRESS TOO HIGH X X

P1668 523489 0 PLV ERROR X X

P0193 157 3 RAIL PRESS SENSOR H RANGE X X

P0192 157 4 RAIL PRESS SENSOR L RANGE X X

P1609 522590 12 SENSOR SUPPLY VOLTAGE1 ERROR X

P1618 522591 12 SENSOR SUPPLY VOLTAGE2 ERROR X

P1619 522592 12 SENSOR SUPPLY VOLTAGE3 ERROR X

P0817 677 5 START INTERLOCK RELAY OPEN CIRCUIT X

P1015 105 3 CHARGE AIR TEMP SENSOR H RANGE X

P1016 105 4 CHARGE AIR TEMP SENSOR L RANGE X

P0217 110 0 X COOLANT TEMP TOO HIGH X X

P0168 174 0 X FUEL TEMP TOO HIGH X X

U0593 522596 19 CAN THROTTLE SIGNAL ERROR TSC1 X

U1305 459726 19 CAN THROTTLE SIGNAL ERROR Y-PM1 X

P0234 102 0 X BOOST PRESS TOO HIGH X X

P1012 94 0 FUEL PRESS TOO HIGH X

P1021 94 18 FUEL PRESS TOO LOW 1 X

50 - TROUBLESHOOTING

Failsafe action
With
DTC SPN FMI DTC description Warn- Level Level Level ENG
FFD
ing 1 2 3 stop
P2530 522308 7 START SWITCH STUCK X

P1013 94 1 FUEL PRESS TOO LOW2 X X

P1014 100 0 LUBE OIL PRESS TOO HIGH X

P1022 100 18 LUBE OIL PRESS TOO LOW 1 X

P0524 523553 1 X LUBE OIL PRESS TOO LOW2 X X

P1017 105 0 CHARGE AIR TEMP TOO HIGH X

P1018 105 1 CHARGE AIR TEMP TOO LOW X

P1019 175 0 LUBE OIL TEMP HIGH X

P1005 522778 7 STOP SWITCH STUCK X

P1008 3359 0 LUBE OIL FILTER CLOGGING X

P0123 91 3 MAIN THROTTLE SENSOR1 H RANGE X X

P0122 91 4 MAIN THROTTLE SENSOR1 L RANGE X X

P0228 29 3 SUB THROTTLE SENSOR H RANGE X

P0227 29 4 SUB THROTTLE SENSOR L RANGE X

U029B 523632 9 SUB CAN THROTTLE COMMUNICATION TSC1 X X

U1306 523633 9 SUB CAN THROTTLE COMMUNICATION Y-PM1 X X

U059C 523632 19 SUB CAN THROTTLE SIGNAL TSC1 X

U1307 523633 19 SUB CAN THROTTLE SIGNAL Y-PM1 X

P0920 773 3 SHIFT FORWARD H RANGE X

P0920 773 4 SHIFT FORWARD L RANGE X

P0924 784 3 SHIFT REVERSE H RANGE X

P0924 784 4 SHIFT REVERSE L RANGE X

P0218 177 0 GEAR OIL TEMP TOO HIGH X

P0710 177 3 GEAR OIL TEMP H RANGE X

P0710 177 4 GEAR OIL TEMP L RANGE X

U103 525 10 CAN COM ERROR X

U100 190 10 CAN COM ERROR ENGINE SPEED X

U404 525 2 CAN COM ERROR SHIFT X

P0560 158 1 BATTERY VOLTAGE TOO LOW X

C1010 521238 3 TANK1 LEVEL SENSOR HIGH RANGE X

C1010 521238 4 TANK1 LEVEL SENSOR LOW RANGE X

C1011 521239 3 TANK2 LEVEL SENSOR HIGH RANGE X

C1011 521239 4 TANK2 LEVEL SENSOR LOW RANGE X

C1051 521240 3 RUDDER ANGLE SENSOR HIGH RANGE X

C1051 521240 4 RUDDER ANGLE SENSOR LOW RANGE X

C1012 521994 13 TANK1 LEVEL CALIBRATION ERROR X

C1013 521995 13 TANK2 LEVEL CALIBRATION ERROR X

C1052 521996 13 RUDDER ANGLE CALIBRATION ERROR X

P1070 521243 3 SEAWATER TEMP SENSOR HIGH RANGE X

P1070 521243 4 SEAWATER TEMP SENSOR LOW RANGE X

C1014 521997 13 SEAWATER TEMP CALIBRATION ERROR X

U2003 521233 4 HOUSE BATTERY VOLTAGE LOW RANGE X

P0840 127 3 GEAR OIL PRESS SENSOR HIGH RANGE X

P0840 127 4 GEAR OIL PRESS SENSOR LOW RANGE X

P1628 630 12 DRIVE-ECU EEPROM ERROR X

P0605 628 12 ROM CRC ABNORMALITY X

U100 523760 9 CAN COM ERROR ENG-ECU TO HELM-ECU X X

U404 523761 9 CAN COM ERROR DRIVE-ECU TO HELM-ECU X X

U1201 523762 9 CAN COM ERROR HELM-ECU TO HELM-ECU X

U1202 523763 9 CAN COM ERROR HELM-LOCAL X X

B1001 523543 4 NEUTRAL SW ACTIVATED X

B1002 523542 4 SELECT SW ACTIVATED X

B1003 523544 4 SYNCH RO SW ACTIVATED X

B1004 523545 4 TROLL SW ACTIVATED X

 TROUBLESHOOTING - 51

Failsafe action
With
DTC SPN FMI DTC description Warn- Level Level Level ENG
FFD
ing 1 2 3 stop
B1005 523541 3 START/STOP SW ACTIVATED X

P0120 91 3 MAIN THROTTLE SENSOR H RANGE X

P0120 91 4 MAIN THROTTLE SENSOR L RANGE X

B1020 91 13 THROTTLE CALIBRATION INCONSISTENCY X

B1043 523768 12 HELM-ECU EEPROM ERROR X

C1208 522041 9 CAN COM ERROR CAN-CONTROL HEAD X X

C1027 522042 11 THROTTLE/SHIFT SENSOR WARNING CAN-CONTROL HEAD X

C1028 522043 11 THROTTLE/SHIFT SENSOR FAILURE CAN-CONTROL HEAD X X

C1029 522044 11 TROLLING SENSOR FAILURE CAN-CONTROL HEAD X X

P1828 522045 1 GEAR OIL PRESS TOO LOW X

U1207 552039 9 CAN COM ERROR SHIFT ACTUATOR X X

B1061 522040 11 SHIFT ACTUATOR FAILURE X X

- IMPORTANT------=
In some cases, this table will not be applicable for optional marine gears and accessories.
Therefore, please refer to each product's operation manual.
52 - TROUBLESHOOTING

Emergency Operation Using the Backup Panel

For any reason, if operation cannot be done with the remote control head, emergency operation can be done by
switching to the backup panel after stopping the engine with the following procedure.
Operation of marine gear shift switch of this panel is applied to only YXH-240-7 marine gear.

- IMPORTANT------=
• Do not use the backup panel unless it is an emergency. Only use this in an emergency.
• Before switching to the backup panel, make sure the engine has stopped and turn OFF "Power switch" in the
switch panel.

START/STOP switch Power switch

Cover Shift switch SUB THROTTLE volume

1. Make sure that "Power switch" of the backup panel is OFF.

2. Remove the shift switch cover, and make sure the shift switch is in NTRL/Neutral.
3. Press "Power switch" to the ON position on the backup panel. "Lamp" will come and control by the backup panel
is enabled.
4. The engine can be started or stopped with "START/STOP switch".
5. Shift gears using the shift switch: FWD/Forward, NTRL/Neutral, REV/Reverse
6.Adjust the engine speed using "SUB THROTTLE volume": Anti-clockwise/lower engine speed, Clockwise/raise
engine speed

- IMPORTANT------=
When using "SUB THROTTLE volume", first turn it fully to the left. Otherwise the engine's turn adjustment will
not work.

7. When stopping the engine, press STOP in "START/STOP switch".

Once the power switch of the backup panel is ON, the system will automatically turn to emergency mode.
Please contact your YAN MAR dealer after returning to the port.

&CAUTION
When steering the ship with the backup panel, please be careful of not only the ships around you but your
own ship's moves as well.
 YANMAR CO., LTD.
■ large Power Products Management Division
Quality Assurance Division
5-3-1, Tsukaguchi-honmachi, Amagasaki
Hyogo,661-0001, Japan
Phone: +81-6-6428-3137 Fax: +81-6-6421-5549

Overseas Office

■ Yanmar Europe B.V. (YEU)

Brugplein 11, 1332 BS Alme re-de Vaart, Netherlands
Phone: +31-36-5493200 Fax: +31-36-5493209

■ Yanmar Asia (Singapore) Corporation Pte. ltd. (YASC)

4 Tuas Lane, Singapore 638613
Phone: +65-6861-3855 Fax: +65-6862-5189

■ Yanmar America Corporation (YA)

101 International Parkway,
Adairsville, GA 30103, U.S.A.
Phone: +1-770-877-9894 Fax: +1-770-877-9009

■ Yanmar Engine (Shanghai) Co., ltd.

Room 1101-1106, No.757 Mengzi Road,
Huangpu District, Shanghai 200023 PRC
Phone: +86-21-2312-0688 Fax: +86-21-6880-8090

■ Yanmar South America lndustria De Maquinas ltda (YSA)

AV. Presidente Vargas, 1400 lndaiatuba/SP
Sao Paulo, Zip Code 13338-901, BRAZIL
Phone: +55-19-3801-9224 Fax: +55-19-3875-3899, 2241

As of September 1st, 2019

0 F' E R.l-\."I" ION MJ.\. N I..J.1-\.1...

6AYEM-GT, 6AYEM-ET

1st edition: October 2019

Issued by: YANMAR CO., LTD. Large Power Products Management Division
Edited by: YANMAR TECHNICAL SERVICE CO., LTD.
VANMAR

YANMAR CO., LTD. 0AAYE-EN0050

2019.10(YTSK)
https://www.yanmar.com PRINTED IN JAPAN