Yanmar 6CX530 Marine Engine Service Manual

Description

• Model List:
  • 6CX530 Marine Engine

• 1. TABLE OFCONTENTS
• 2. INTRODUCTION
• 3. GENERAL SERVICEINFORMATION
• 3.1. SAFETY PRECAUTIONS
• 3.2. X530 EXTERIOR VIEWS
• 3.3. DIESEL FUEL
• 3.4. ENGINE OIL
• 3.5. MARINE GEAR
• 3.6. ENGINE COOLANT
• 3.7. CHECKING THE ENGINE OILAND ENGINE COOLANT
• 3.8. ENGINE OUTLINE DRAWINGS
• 3.9. EXHAUST GAS EMISSION REGULATIONS
• 3.10. LOCATION OF NAMEPLATES
• 3.11. X530 ENGINE SPECIFICATIONS
• 3.12. ABBREVIATIONS AND SYMBOLS
• 3.13. UNIT CONVERSIONS
• 4. PERIODICMAINTENANCE
• 4.1. SAFETY PRECAUTIONS
• 4.2. INTRODUCTION
• 4.3. EPA MAINTENANCEREQUIREMENTS
• 4.4. PERIODIC MAINTENANCESCHEDULE
• 4.5. PERIODIC MAINTENANCEPROCEDURES
• 4.6. LONG-TERM STORAGE(COOLING SYSTEM)
• 4.7. SAFETY PRECAUTIONS
• 4.8. INTRODUCTION
• 4.9. DISASSEMBLING THE ENGINEAND COMPONENTS
• 4.10. INSPECTING THE CYLINDERBLOCK AND COMPONENTS
• 4.11. ASSEMBLING THE ENGINE ANDCOMPONENTS
• 5. FUEL SYSTEM
• 5.1. SAFETY PRECAUTIONS
• 5.2. INTRODUCTION
• 5.3. SPECIFICATIONS
• 5.4. FUEL HIGH-PRESSURE SUPPLYPUMP / FUEL FEED PUMP /FUEL PRIMING PUMP
• 5.5. FUEL INJECTOR COMPONENTSAND FUNCTIONS
• 5.6. FUEL FEED PUMPCOMPONENTS ANDFUNCTIONS
• 5.7. FUEL / WATER SEPARATORCOMPONENTS ANDFUNCTIONS
• 5.8. FUEL FILTER AND FUNCTIONS
• 5.9. ENGINE CONTROL SYSTEMDIAGRAM
• 6. COOLING SYSTEM
• 6.1. SAFETY PRECAUTIONS
• 6.2. INTRODUCTION
• 6.3. COOLING SYSTEMCOMPONENTS ANDFUNCTIONS
• 6.4. SEAWATER PUMPCOMPONENTS ANDFUNCTIONS
• 6.5. COOLANT PUMP COMPONENTSAND FUNCTIONS
• 6.6. HEAT EXCHANGERCOMPONENTS ANDFUNCTIONS
• 6.7. COOLANT RECOVERY TANKCOMPONENTS ANDFUNCTIONS
• 6.8. THERMOSTAT COMPONENTSAND FUNCTIONS
• 6.9. SEACOCK COMPONENTS ANDFUNCTIONS (OPTIONAL)
• 6.10. X530 Service Manual 7-21 2009 Yanmar Marine InternationalBILGE PUMP AND STRAINER COMPONENTS AND FUNCTIONS(OPTIONAL)
• 6.11. BILGE PUMP AND STRAINER COMPONENTS AND FUNCTIONS(OPTIONAL)
• 7. LUBRICATION
• 7.1. SAFETY PRECAUTIONS
• 7.2. INTRODUCTION
• 7.3. LUBRICATION COMPONENTSAND FUNCTIONS
• 7.4. OIL PUMP COMPONENTS ANDFUNCTIONS
• 7.5. OIL FILTER COMPONENTS ANDFUNCTIONS
• 7.6. OIL COOLER FUNCTIONS
• 8. TURBOCHARGER
• 8.1. SAFETY PRECAUTIONS
• 8.2. INTRODUCTION
• 8.3. TURBOCHARGER COMPONENTS AND FUNCTIONS
• 8.4. DISASSEMBLING THE TURBOCHARGER
• 8.5. ASSEMBLING THE TURBOCHARGER
• 8.6. MAINTENANCE STANDARD CHART
• 8.7. TIGHTENING TORQUE CHART
• 8.8. HANDLING THETURBOCHARGER
• 8.9. TROUBLESHOOTING THETURBOCHARGER
• 9. STARTER
• 9.1. SAFETY PRECAUTIONS
• 9.2. INTRODUCTION
• 9.3. STARTER COMPONENTS ANDFUNCTIONS
• 9.4. ALTERNATOR
• 9.5. SAFETY PRECAUTIONS
• 9.6. INTRODUCTION
• 9.7. ALTERNATOR COMPONENTSAND FUNCTIONS
• 10. ELECTRICAL
• 10.1. SAFETY PRECAUTIONS
• 10.2. INTRODUCTION
• 10.3. BATTERY COMPONENTS ANDFUNCTIONS
• 10.4. WIRING DIAGRAM
• 10.5. WARNING DEVICES
• 10.6. AIR HEATER COMPONENTSAND FUNCTIONS
• 10.7. FUSE, RELAY AND HARNESSCOMPONENTS
• 10.8. REMOTE CONTROL ELECTRONIC CONTROL SYSTEM (ECS)
• 11. TROUBLESHOOTING
• 11.1. SAFETY PRECAUTIONS
• 11.2. INTRODUCTION
• 11.3. PREPARATION BEFORETROUBLESHOOTING
• 11.4. TROUBLESHOOTING PROCEDURE
• 11.5. TROUBLESHOOTING BY SYMPTOM
• 11.6. TROUBLESHOOTING BY DTC FAULT CODES
• 12. DTCS (DIAGNOSTIC TROUBLE CODES) GENERALDESCRIPTION
• 12.1. DTC Code List
• 12.2. Description Items
• 12.3. Analog Input
• 12.3.1. Rail Pressure Sensor 1
• 12.3.2. Rail Pressure Sensor 2
• 12.3.3. Boost Pressure Sensor
• 12.3.4. Coolant Temperature Sensor
• 12.3.5. Intake Air Temperature Sensor
• 12.3.6. Inlet Fuel Temperature Sensor
• 12.3.7. Outlet Fuel Temperature Sensor
• 12.3.8. Engine Oil Pressure Sensor
• 12.3.9. Exhaust Temperature Sensor
• 12.3.10. Main Throttle Position Sensor
• 12.3.11. Sub-Throttle Position Sensor
• 12.3.12. CAN Throttle
• 12.3.13. ECU Temperature Sensor
• 12.3.14. Sensor 5V – 1
• 12.3.15. Sensor 5V – 2
• 12.4. Pulse input
• 12.4.1. Cam Sensor 1
• 12.4.2. Crank Sensor 1
• 12.4.3. Cam Sensor 2
• 12.4.4. Crank Sensor 2
• 12.4.5. Cam Sensor 1 Crank Sensor 1
• 12.4.6. Cam Sensor 2 Crank Sensor 2
• 12.5. Actuator Drive
• 12.5.1. Pressure Control Valve 1 (PCV1)
• 12.5.2. Pressure Control Valve 2 (PCV2)
• 12.5.3. Injector Circuit (No. 1 to No. 6)
• 12.5.4. Injector Communication Power
• 12.5.5. Pressure Relief Valve (PRV)
• 12.5.6. PCV Relay
• 12.5.7. Pressure Relief Valve (PRV) Relay
• 12.5.8. Engine Driver Unit (EDU) Relay
• 12.5.9. Intake Air Heater Relay
• 12.5.10. Main Relay
• 12.6. Engine
• 12.6.1. Supply Pump Pressure Too High
• 12.6.2. Fuel Pumping Timing Advanced Too Much
• 12.6.3. Supply Pump Pressure Too Low
• 12.6.4. Supply Pump Feed Back Value Failure
• 12.6.5. Rail Pressure Too High
• 12.6.6. Rail Pressure Too High (Over Limit)
• 12.6.7. Coolant Temperature Too High
• 12.6.8. Boost Pressure Too High
• 12.6.9. Inlet Fuel Temperature Too High
• 12.6.10. Outlet Fuel Temperature Too High
• 12.6.11. Engine Oil Pressure Too Low
• 12.6.12. Battery Voltage Too High
• 12.6.13. Battery Voltage Too Low
• 12.6.14. Engine Over Speed
• 12.7. ECU
• 12.7.1. ECU Temperature Too High
• 12.7.2. ECU EEPROM (Initialization)
• 12.7.3. ECU EEPROM (Single Domain)
• 12.7.4. ECU EEPROM (Triple Domain)
• 12.7.5. ECU ROM (INDMAP)
• 12.7.6. ECU ROM (MAP Domain)
• 12.7.7. ECU ROM (APL Domain)
• 12.7.8. Injector QR Correction Value
• 13. METHOD AND PROCEDURE OF FAILURE DIAGNOSIS
• 13.1. Description Items
• 13.2. ECU Pin Layout Drawing
• 13.3. Using a Breakout Box
• 13.4. Checking Trouble Code (P Code) with the Yanmar Diagnostic Tool (YDT)
• 13.5. Analog Input
• 13.5.1. Pressure Sensor
• 13.5.2. Temperature Sensor
• 13.5.3. Analog Throttle Sensor
• 13.5.4. CAN Throttle
• 13.5.5. Sensor Power Supply
• 13.6. Pulse Input
• 13.6.1. Crank Sensor
• 13.6.2. Cam Sensor
• 13.7. Actuator Drive
• 13.7.1. Pressure Control Valve
• 13.7.2. Injector
• 13.7.3. Pressure Relief Valve
• 13.7.4. Relay
• 13.7.5. Main Relay
• 14. SERVICESTANDARDS
• 14.1. SERVICE STANDARDS
• 14.2. TIGHTENING TORQUE FOR BOLTS AND NUTS