Yanmar 6LY2-STE, 6LY2A-STIP, 6LYA-STP Marine Diesel Engine Service Manual

Description

• Model List:
  • 6LY2-STE, 6LY2A-STIP, 6LYA-STP Marine Diesel Engine

• 1. FOREWORD
• 2. CHAPTER 1.GENERAL
• 2.1. Exterior Views
• 2.2. Specifications
• 2.3. Performance Curves
• 2.4. Dimensions
• 2.5. Wiring Diagrams
• 2.6. Piping Diagrams
• 3. CHAPTER 2.INSPECTION AND SERVICING OF BASIC ENGINE PARTS
• 3.1. Cylinder Block
• 3.1.1. Inspection of parts
• 3.1.2. Cleaning of oil holes
• 3.1.3. Color check procedure
• 3.1.4. Replacement of cup plugs
• 3.1.5. Cylinder bore measurement
• 3.2. Cylinder Head
• 3.2.1. Inspecting the cylinder head
• 3.2.2. Valve seat correction procedure
• 3.2.3. Intake/exhaust valves,valve guides
• 3.2.4. Valve springs
• 3.2.5. Assembling the cylinder head
• 3.2.6. Measuring top clearance
• 3.2.7. Intake and exhaust valve arms
• 3.2.8. Adjustment of valve clearance
• 3.2.9. Checking and adjusting the fuel injection timing
• 3.3. Piston and Piston Pins
• 3.3.1. Piston
• 3.3.2. Piston Pin
• 3.3.3. Piston rings
• 3.4. Connecting Rod
• 3.4.1. Inspecting the connection rod
• 3.4.2. Crank pin bearing
• 3.4.3. Piston pin bearing
• 3.4.4. Assembling piston and connecting rod
• 3.5. Crankshaft and Main Bearing
• 3.5.1. Crankshaft
• 3.5.2. Main bearing
• 3.6. Camshaft and Tappets
• 3.6.1. Camshaft
• 3.6.2. Tappets
• 3.7. Timing Gear
• 3.7.1. Inspecting the gears
• 3.7.2. Gear timing marks
• 3.8. Flywheel
• 3.8.1. Specifications of flywheel
• 3.8.2. Dimensions of flywheel and mounting flange
• 3.8.3. Ring gear
• 3.8.4. Position of top dead center and fuel injection timing
• 4. CHAPTER 3.FUEL INJECTION EQUIPMENT
• 4.1. Fuel injection Pump Construction
• 4.2. Fuel injection pump Specifications
• 4.3. Fuel supply System
• 4.3.1. Fuel supply system
• 4.3.2. Functioning of fuel injection pump
• 4.3.3. Injection volume control
• 4.3.4. Governor construction
• 4.3.5. Types of governor according to structure
• 4.3.6. Idling and Maximum speed
• 4.4. Fuel Injection Nozzle
• 4.4.1. Functioning of fuel injection nozzle
• 4.4.2. Fuel injection nozzle disassembly
• 4.4.3. Fuel injection nozzle inspection
• 4.4.4. Adjusting fuel injection nozzle
• 4.5. Fuel Feed Pump
• 4.6. Disassembly, Reassembly and Inspection of Governor
• 4.6.1. Governor disassembly
• 4.6.2. Inspection of governor
• 4.6.3. Assembling the governor
• 4.7. Disasembly,Reassembly and Inspection of Fuel injection pump
• 4.7.1. Disassembly of fuel injection pump
• 4.7.2. Inspection of fuel injection pump
• 4.7.3. Reassembly of fuel injection pump
• 4.7.4. Adjustment of Pre-stroke
• 4.7.5. Adjusting injection timing
• 4.7.6. Plunger pressure test
• 4.7.7. Delivery valve pressure test
• 4.7.8. Adjusting injection volume(uniformity of each cylinder)
• 4.7.9. Adjustment of governor
• 4.7.10. Adjustment of torque rise
• 4.8. Automatic Advancing Timer
• 4.8.1. Timer construction
• 4.8.2. Function and characteristics of timer
• 4.8.3. Timer disassembly
• 4.8.4. Timer inspection
• 4.8.5. Timer reassembly
• 4.9. Fuel feed pump
• 4.9.1. Fuel Feed Pump Disassembly
• 4.9.2. Fuel Feed Pump Inspection
• 4.9.3. Fuel Feed Pump Reassembly
• 4.9.4. Fuel Feed Pump Adjustment
• 4.10. Adjustment of Fuel Injection Pump and Governor
• 4.10.1. Preparations
• 4.10.2. Nozzle inspection
• 4.10.3. Fuel injection nozzle reassembly
• 4.11. Fuel Filter
• 4.11.1. Fuel filter specifications
• 4.11.2. Fuel filter inspection
• 5. CHAPTER 4.TURBOCHARGER SYSTEM
• 5.1. Construction and Function
• 5.1.1. Outline
• 5.2. Standards for Maintenance and Check
• 5.2.1. Standards for Maintenance and Check
• 5.2.2. Tightening Torque
• 5.3. Periodical Checking Procedure
• 5.3.1. Periodical Checking Interval
• 5.3.2. Checking Procedure
• 5.4. Disassembly Procedure
• 5.4.1. Preparations for Disassembly
• 5.4.2. Check before Disassembly
• 5.4.3. Disassembly
• 5.5. Cleaning and Checking Procedure
• 5.5.1. Cleaning
• 5.5.2. Checking Procedure
• 5.6. Reassembling procedure
• 5.6.1. Preparations for Reassembly
• 5.6.2. Reassembling procedure
• 5.7. Handling After Reassembly
• 5.7.1. Precautions for mounting the turbocharger to the engine
• 5.8. Troubleshooting
• 5.8.1. Exhaust gas is dense
• 5.8.2. Whitish exhaust gas
• 5.8.3. Too early oil shortage
• 5.8.4. Output drop
• 5.8.5. Poor follow-up of supercharger
• 5.8.6. Unusual sound or vibration
• 6. CHAPTER 5.LUBRICATION SYSTEM
• 6.1. Lubrication System
• 6.2. Lube Oil Pump
• 6.2.1. Lube oil pump construction
• 6.2.2. Specifications of lube oil pump
• 6.2.3. Removal
• 6.2.4. Inspection
• 6.2.5. Instllation
• 6.3. Lube Oil Filter
• 6.3.1. Lube oil filter construction
• 6.3.2. Lube oil filter replacement
• 6.4. Oil Pressure Control Valve
• 6.4.1. Oil pressure control valve construction
• 6.4.2. Oil pressure control valve replacement
• 6.5. Lube Oil Cooler
• 6.5.1. Lube oil cooler construction
• 6.5.2. Inspecting the lube oil cooler
• 6.6. Piston Cooling Nozzle
• 6.6.1. Piston cooling nozzle construction
• 6.6.2. Inspection of piston cooling nozzle
• 6.7. Rotary Waste Oil Pump(Optional)
• 6.7.1. Construction
• 6.7.2. Inspection the waste oil pump
• 7. CHAPTER 6.COOLING WATER SYSTEM
• 7.1. Cooling Water System
• 7.1.1. System
• 7.1.2. Water leakage test(Fresh water)
• 7.1.3. Removing Scale(During Disassembly)
• 7.1.4. Anti-Corrosion Agent
• 7.1.5. Antifreeze
• 7.2. Sea Water Pump
• 7.2.1. Sea water pump construction and functioning
• 7.2.2. Sea water pump disassembly
• 7.2.3. Sea water pump inspection
• 7.2.4. Sea water pump reassembly
• 7.3. Fresh Water Pump
• 7.3.1. Fresh water pump construction
• 7.3.2. Specifications of fresh water pump
• 7.3.3. Fresh water pump disassembly
• 7.3.4. Fresh water pump reassembly
• 7.4. Fresh Water Cooler
• 7.4.1. Fresh water cooler construction
• 7.4.2. Specifications of heat exchanger
• 7.4.3. Disassembly and reassembly of the fresh water cooler
• 7.4.4. Fresh water cooler inspection
• 7.5. Pressure Cap and Sub Tank
• 7.5.1. Pressure cap construction
• 7.5.2. Pressure cap pressure control
• 7.5.3. Pressure cap inspection
• 7.5.4. Function of the sub tank
• 7.5.5. Specifications of sub tank
• 7.5.6. Mounting the sub tank
• 7.5.7. Precautions on usage of the sub tank
• 7.6. Thermostat
• 7.6.1. Functioning of thermostat
• 7.6.2. Thermostat construction
• 7.6.3. Characteristics of thermostat
• 7.6.4. Thermostat inspection
• 7.6.5. Testing the thermostat
• 7.7. Kingston Cock(Optional)
• 7.7.1. Construction
• 7.7.2. Handling precautions
• 7.7.3. Inspection
• 8. CHAPTER 7.REDUCTION AND REVERSING GEAR
• 8.1. Specification and System
• 8.1.1. Marine Gears(YANMAR MODEL KMH6A1)
• 8.2. Readdembly and disassembly(KMH6A1)
• 8.2.1. Disassembly
• 8.2.2. Disassembling input and output gears
• 8.2.3. Disassembling support shafts A and B
• 8.2.4. Disassembling valve body
• 8.3. Cautions for Reassembly
• 8.3.1. Cautions for Reassembly
• 8.3.2. Tightening Torque of Major Bolts
• 8.3.3. Standerd Tightening Torque
• 9. CHAPTER 8.REMOTO CONTROL(OPTIONAL)
• 9.1. Remoto Control System(Option)
• 9.1.1. Construction of remoto control system
• 9.1.2. Remoto control device components
• 9.2. Remoto Control Installation
• 9.2.1. Speed control
• 9.2.2. Ahead-neutral-astern control
• 10. CHAPTER 9.ELECTRICAL SYSTEM
• 10.1. System Diagram
• 10.1.1. System diagram of electric parts
• 10.2. Battery
• 10.2.1. Construnctlon
• 10.2.2. Battery capacity and battery cables
• 10.2.3. Inspection
• 10.2.4. Charging
• 10.2.5. Battery storage precautions
• 10.3. Starter Motor
• 10.3.1. Specifications and Performance
• 10.3.2. Features
• 10.3.3. Construction
• 10.3.4. Disassembly
• 10.3.5. Maintenance standerd
• 10.3.6. Inspection
• 10.3.7. Reassembly precautions
• 10.3.8. Adjustment and performance test
• 10.3.9. Testing
• 10.3.10. Troubleshooting
• 10.4. Alternator
• 10.4.1. Features
• 10.4.2. Specifications
• 10.4.3. Characteristics
• 10.4.4. Construction
• 10.4.5. Alternator functioning
• 10.4.6. Handling precautions
• 10.4.7. Disassembling the alternator
• 10.4.8. Inspection and adjustment
• 10.4.9. Reassembling the alternator
• 10.4.10. Performamce test
• 10.4.11. Troubleshooting
• 10.5. Instrument Panel
• 10.6. Warning Devices
• 10.6.1. Oil pressure alarm
• 10.6.2. Cooling water temperature alarm
• 10.6.3. Sender unit for lube pressure gauge
• 10.6.4. Sender unit for the cooling water temperature gauge
• 10.7. Tachometer
• 10.7.1. Construction of tachometer
• 10.7.2. Specifications and dimensions of tachometer
• 10.7.3. Measurement of sensor unit characteristics
• 10.7.4. Diagnosis
• 11. CHAPTER 10.DISASSEMBLY AND REASSEMBLY
• 11.1. Disassembly and Reassembly precautions
• 11.2. Disassembly and Reassembly Tools
• 11.2.1. Special Handtools
• 11.2.2. Measuring Instruments
• 11.2.3. Other material
• 11.3. Disassembly and Reassembly
• 11.3.1. Disassembly
• 11.3.2. Reassembly
• 11.4. Main parts spec./ tightening torque
• 11.4.1. Quality control points
• 11.4.2. Dimension of Main Parts
• 11.4.3. Bolt/Nut Tightening torque
• 11.5. Test running
• 11.5.1. Preliminary Precautions
• 11.5.2. Check Points and Precautions During Running
• 12. CHAPTER 11.TROUBLESHOOTING
• 12.1. Troubleshooting
• 13. BACK COVER