Yanmar 6LY2-STE Manuals

Manuals and User Guides for Yanmar 6LY2-STE. We have 1 Yanmar 6LY2-STE manual available for free PDF download: Service Manual

Yanmar 6LY2-STE Service Manual (235 pages)

Brand: Yanmar | Category: Engine | Size: 8.29 MB

Index
5
General
6
For Safe Servicing
7
Precautions
8
Location of Product Safety Labels
12
Exterior Views
13
Specifications
14
Performance Curve
16
Dimensions
19
Inspection and Servicing of Basic Engine Parts
27
Cylinder Block
28
Inspection of Parts
28
Cleaning of Oil Holes
28
Color Check Procedure
28
Replacement of Cup Plugs
29
Cylinder Bore Measurement
30
Cylinder Sleeve
31
Measurement of Sleeve
31
Inserting of Cylinder Sleeve
31
Measurement of Projection
31
Cylinder Head
32
Inspection the Cylinder Head
33
Distortion of the Combustion Surface
33
Checking for Cracks in the Combustion Surface
33
Checking the Intake and Exhaust Valve Seats
33
Valve Seat Correction Procedure
34
Intake/Exhaust Valves, Valve Guides
34
Wearing and Corrosion of Valve Stem
34
Inspection of Valve Seat Wear and Contact Surface
35
Valve Sinking
35
Valve Springs
36
Valve Stem Seals
36
Spring Retainer and Spring Cotter
36
Assembling the Cylinder Head
37
Measuring Top Clearance
37
Intake and Exhaust Valve Rocker Arms
37
Adjustment of Valve Clearance
38
Rocker Arm Shaft and Valve Rocker Arm Bushing
38
Valve Spring
38
Rocker Arm and Cotter Wear
38
Checking and Adjusting the Fuel Injection Timing
39
Piston and Piston Rings
40
Piston Head and Combustion Surface
40
Measurement of Piston Outside Diameter/Inspection
40
Replacing the Piston
41
Piston Pin
41
Piston Rings
41
Measuring Piston Ring End Gap
42
Replacing the Piston Rings
42
Connecting Rod
44
Inspecting the Connection Rod
44
Twist and Parallelism of the Large and Small Ends
44
Checking Thrust Clearance
44
Crank Pin Bearing
45
Piston Pin Bearing
45
Measuring Crank Pin Oil Clearance
45
Precautions on Replacement of Crank Pin Bearing
45
Assembling Piston and Connecting Rod
46
Crankshaft and Main Bearing
47
Color Check of Shaft
47
Bending of the Crankshaft
48
Measuring the Crank Pin and Journal
48
Main Bearing
49
Checking Side Clearance of the Crankshaft
49
Camshaft
50
Checking the Camshaft Side Gap
50
Tappets
51
Timing Gear
53
Inspecting the Gears
53
Idle Gear
53
Gear Timing Marks
54
Flywheel
55
Specifications of Flywheel
55
Dimensions of Flywheel and Mounting Flange
56
Fling Gear
57
Position of Top Dead Center and Fuel Injection Timing
57
Fuel Injection Equipment
58
Fuel Injection Pump Construction
59
Fuel Injection Pump Specifications
60
Fuel Supply System
61
Functioning of Fuel Injection Pump
61
Injection Volume Control
62
Governor Construction
63
Types of Governor According to Structure
64
Shape of Control and Stop Levers
64
Engine Stop Device
64
Torque Rise Equipment
64
Boost Compensator
65
Objective of Compensator
65
Outline of Structure and Principle of Operation
65
Operation of Cancel Knob
66
Adjustment of Boost Compensator
66
Idling
67
Maximum Spsed
67
Adjustment of Fuel Injection Timing
67
Fuel Injection Nozzle
68
Hole Type Fuel Injection Nozzle
68
Functioning of Fuel Injection Nozzle
68
Fuel Injection Nozzle Disassembly
69
Fuel Injection Nozzle Inspection
69
Washing
69
Adjusting Fuel Injection Nozzle
70
Adjusting Opening Pressure
70
Injection Test
70
Fuel Feed Pump
71
Fuel Feed Pump Design and Function
71
Disassembly, Reassembly and Inspection of Governor
72
Governor Disassembly
73
Inspection of Governor
74
Assembling the Governor
76
Disassembly, Reassembly and Inspection of Fuel Injection Pump
78
Disassembly of Fuel Injection Pump
79
Inspection of Fuel Injection Pump
82
Reassembly of Fuel Injection Pump
83
Adjustment of Pre-Stroke
86
Adjusting Injection Timing
87
Plunger Pressure Test
87
Delivery Valve Pressure Test
87
Adjusting Injection Volume
88
Adjustment of Governor
88
Measuring Injection Volume
88
Adjustment Injection Volume
88
Adjustment of Torque Rise
89
Adjusting Idling
89
Check Injection Stop
89
Models with Angleich Spring
89
Smoke Cut Spring
90
Service Data
91
Automatic Advancing Timer
92
Timer Construction
92
Function and Characteristics of Timer
92
Timer Disassembly
93
Timer Inspection
93
Timer Reassembly
93
Fuel Feed Pump Disassembly
94
Fuel Feed Pump Inspection
94
Fuel Feed Pump Reassembly
94
Automatic Pressure Control Mechanism
94
Fuel Feed Pump Adjustment
95
Adjustment of Fuel Injection Pump and Governor
96
Nozzle Inspection
97
Fuel Injection Nozzle Reassembly
97
Fuel Filter
98
Fuel Filter Specifications
98
Fuel Filter Inspection
98
Turbocharger System
99
Construction and Function
100
Outline
100
Bearings
100
Sealing Mechanism at Blower Side
100
Standards for Maintenance and Check
101
Tightening Torque
102
Periodical Checking Procedure
103
Periodical Checking Interval
103
Checking of Play of Rotor
104
Disassembly Procedure
105
Check before Disassembly
106
Removal of Turbine Housing
106
Removal of Turbine Shaft
106
Removal of Seal Plate
106
Cleaning and Checking Procedure
107
Checking before Cleaning
107
Blower Wheel Chamber
109
Turbine Wheel Chamber
109
Blower Wheel
109
Turbine Shaft
109
Floating Metal
110
Bearing Wheel Cleaning
110
Sealing Plate
111
Wastegate Actuator
111
Reassembling Procedure
112
Reassembling of Floating Metal
112
Reassembling of Turbine Shaft
112
Mounting of Thrust Metal
112
Mounting of Sealing Plate
113
Mounting of Blower Wheel
113
Mounting of Turbine Housing
113
Mounting of Blower Wheel Chamber
113
Connection of Boost Hose
114
Measurement of Play of Rotor
114
Handling after Reassembly
115
Precautions for Mounting the Turbocharger to the Engine
115
Troubleshooting
116
Exhaust Gas Is Dense
116
Whitish Exhaust Gas
117
Too Early Oil Shortage
117
Output Drop
117
Poor Follow-Up of Supercharger
117
Unusual Sound or Vibration
118
Lubrication System
119
Lube Oil Pump
121
Lube Oil Pump Construction
121
Specifications of Lube Oil Pump
121
Lube Oil Filter
124
Lube Oil Filter Construction
124
Lube Oil Filter Replacement
124
Oil Pressure Control Valve
125
Lube Oil Cooler
126
Piston Cooling Nozzle
127
Piston Cooling Nozzle Construction
127
Inspection of Piston Cooling Nozzle
127
Rotary Waste Oil Pump
128
Inspecting the Waste Oil Pump
128
Cooling Water System
129
Water Leakage Test
131
Removing Scale
131
Anti-Corrosion Agent
131
Antifreeze
131
Sea Water Pump
132
Sea Water Pump Disassembly
133
Sea Water Pump Inspection
133
Sea Water Pump Reassembly
133
Fresh Water Pump
134
Specifications of Fresh Water Pump
135
Fresh Water Pump Disassembly
135
Fresh Water Pump Inspection
135
Fresh Water Cooler
137
Specifications of Heat Exchanger
138
Disassembly and Reassembly of the Fresh Water Cooler
138
Fresh Water Cooler Inspection
138
Pressure Cap Construction
139
Pressure Cap Control
139
Pressure Cap Inspection
139
Function of the Sub Tank
139
Specifications of Sub Tank
140
Mounting the Sub Tank
140
Precautions on Usage of the Sub Tank
140
Thermostat
141
Thermostat Inspection
142
Testing the Thermostat
142
Kingston Cock
143
Reduction and Reversing Gear
144
Marine Gears
145
Major Specifications
145
Hydraulic System
147
Handling of Emergency Bolts
148
Disassembling Input and Output Gears
150
Disassembling Support Shafts a and B
150
Disassembling Valve Body
151
Cautions for Reassembly
152
Tightening Torque of Major Bolts
154
Standard Tightening Torque
154
Handling of Hydraulic Pump
154
Remote Control
155
Construction of Remote Control System
156
Remote Control Device Components
156
Remote Control Installation
157
Speed Control
157
Ahead-Neutral-Astern Control
157
Electrical System
158
System Diagram
159
System Diagram of Electric Parts
159
Battery Construction
160
Checking the Electrolyte
161
Voltage Test
161
Washing the Battery
161
Charging Methods
162
Charging Procedure
162
Charging Precautions
162
Battery Storage Precautions
162
Starter Motor
163
Armature
168
Armature Coil Continuity and Ground Test
168
Field Coil
169
Reassembly Precautions
170
Magnetic Switch
170
Pinion
170
Ball Bearing
170
Testing
171
No Load Test
171
Pinion Movement
171
Plunger Movement
171
Starter Motor Troubleshooting
172
Alternator Features
173
Alternator Specifications
173
Alternator Characteristics
173
Alternator Construction
174
Alternator Functioning
175
Disassembling the Alternator
176
Reassembling the Alternator
179
IC Regulator
179
Performance Test
180
Assembling the Rear Cover
180
Measuring the Regulating Voltage
180
Charging Failure
181
Overcharging
182
Charge Lamp Failure
182
Instrument Panel
183
Warning Devices
184
Oil Pressure Alarm
184
Cooling Water Temperature Alarm
185
Sender Unit for Lube Oil Pressure Gauge
185
Sender Unit for the Cooling Water Temperature Gauge
186
Lube Oil Pressure Sender Unit
186
Damper
186
Tachometer
187
Specifications and Dimensions of Tachometer
187
Measurement of Sensor Unit Characteristics
188
Disassembly and Reassembly
189
Disassembly and Reassembly Tools
191
Drain Cooling Water
200
Drain Lube Oil
200
Removing Wiring
201
Removing the Fuel Oil Filter & Fuel Oil Pipe
201
Removing the Intake Silencercer
201
Removing the Mixing Elbow
201
Removing the Intercooler
202
Removing the Starting Motor
203
Removing the Alternator
203
Removing the Cooling Water Pipe
203
Removing the Cylinder Head
204
Tappet
206
Cam Shaft Bearing
206
Gear Case
208
Cam Shaft
208
Piston Assembly
208
Oil Pan Spacer
209
Lube Oil Intake Pipe and Delivery Pipe
209
Oil Pan
209
Flywheel Housing
209
Seawater Pump
210
Lube Oil Pressure Regulating Valve
210
Cooling Water Passage Cover
210
Fuel Injection Pump
210
Oil Seal
211
Cylinder Head Assembly
211
Turbine Cooling Fresh Water (CWF) Pipe
212
Intercooler
212
Intake Manifold
212
Marine Gear KMH6A1
212
Push Rod, Valve Arm Shaft Assembly
213
Gear Case Cover
213
Crank V-Pulley
214
Fuel Injection Valve
214
Fresh Water Tank
215
Cooling Water Bend
216
Air Duct
216
Intercooler Steady Brace
216
Boost Output Pipe
216
Lube Oil Cooler Assembly
217
Turbocharger
217
Mixing Elbow
217
Alternator
217
Starting Motor
218
Cooling Water Pipe
218
Dipstick
218
Main Parts Spec./Tightening Torque
219
Quality Control Points
219
Test Running
227
Preliminary Precautions
227
Check Points and Precautions During Running
227

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Yanmar 6LY2-STE Service Manual (235 pages)

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