Yanmar 6LYA-STE Manuals

Manuals and User Guides for Yanmar 6LYA-STE. We have 3 Yanmar 6LYA-STE manuals available for free PDF download: Service Manual, Operation Manual

Yanmar 6LYA-STE Service Manual (215 pages)

Brand: Yanmar | Category: Engine | Size: 14.69 MB

Index
4
General Information
5
Exterior Views: Non-Operating Side/Operating Side
6
Specifications/Engine
7
Performance Curves 6LYA-UTE
8
Performance Curves 6LYA-STE
9
Dimensions
10
With KMH6A Marine Gear Diagrams
11
Wiring Diagrams
12
New B-Type Instrument Panel Diagram
12
New C-Type Instrument Panel Diagram
13
New D-Type Instrument Panel Diagram
14
Piping Diagrams
15
Inspection and Servicing of Basic Engine Parts
16
Cylinder Block
17
Cleaning of Oil Holes
17
Color Check Procedure
17
Replacement of Cup Plugs
18
Cylinder Bore Measurement
19
Cylinder Sleeve
20
Measurement of Sleeve
20
Insertion of Cylinder Sleeve
20
Measurement of Projection
20
Cylinder Head
21
Inspecting the Cylinder Head
22
Distortion of the Combustion Surface
22
Checking for Cracks in the Combustion Surface
22
Checking the Intake and Exhaust Valve Seats
22
Valve Seat Correction Procedure
23
Wearing and Corrosion of Valve Stem
23
Intake/Exhaust Valves, Valve Guides
23
Inspection of Valve Seat Wear and Contact Surface
24
Valve Sinking
24
Valve Stem Seals
25
Checking Valve Springs
25
Measure Spring Tension
25
Spring Retainer and Spring Cotter
25
Assembling the Cylinder Head
26
Measuring Top Clearance
26
Intake and Exhaust Valve Arms
26
Adjustment of Valve Clearance
27
Checking and Adjusting the Fuel Injection Timing
28
Vale Opening Diagram
28
Piston and Piston Pins
29
Piston Head and Combustion Surface
29
Measurement of Piston Outside Diameter/Inspection
29
Replacing the Piston
30
Piston Pin/Piston Rings
30
Measuring the Rings
30
Measuring Piston Ring Gap
31
Replacing the Piston Rings
31
Inspecting the Connection Rod
33
Crank Pin Bearing
34
Inspecting Piston Pin Bearing
34
Assembling Piston and Connecting Rod
35
Crankshaft and Main Bearing
36
Crankshaft
36
Bending of the Crankshaft
37
Measuring the Crank Pin and Journal
37
Checking Side Clearance of the Crankshaft
38
Main Bearing
38
Camshaft
39
Tappets
40
Timing Gear
42
Flywheel
44
Dimensions of Flywheel and Mounting Flange
45
Ring Gear
46
Position of Top Dead Center and Fuel Injection Timing
46
Fuel Injection Equipment. Table of Contents
47
Fuel Injection Pump Construction
48
Fuel Injection Pump Specifications
49
Fuel Supply System
50
Functioning of Fuel Injection Pump
50
Injection Volume Control
51
Full Injection Volume Position
51
Half Injection Volume Position
51
No Fuel Injection
51
Governor Construction
52
Types of Governor According to Structure
53
Shape of Control and Stop Levers/Engine Stop Device
53
Torque Rise Equipment
53
Smoke Cut Device
53
Boost Compensator
54
Objective of Compensator
54
Outline of Structure and Principle of Operation
54
Operation of Cancel Knob
55
Adjustment of Boost Compensator
55
Idling and Maximum Speed
56
Adjustment of Fuel Injection Timing
56
Functioning of Fuel Injection Nozzle
57
Hole Type Fuel Injection Nozzle Diagram
57
Fuel Injection Nozzle Disassembly
58
Fuel Injection Nozzle Inspection
58
Adjusting Fuel Injection Nozzle
59
Adjusting Opening Pressure
59
Injection Test
59
Fuel Feed Pump Design and Function
60
Disassembly, Reassembly and Inspection of Governor
61
Governor Disassembly
62
Inspection of Governor Weight Assembly
63
Inspection of Governor Sleeve
64
Inspection of Governor Lever Assembly
64
Inspection of Springs
64
Inspection of Torque Spring Assembly
64
Assembling the Governor
65
Disassembly, Reassembly and Inspection of Fuel Injection Pump
67
Disassembly of Fuel Injection Pump
68
Inspection of Fuel Injection Pump
71
Reassembly of Fuel Injection Pump
72
Adjustment of Pre-Stroke
75
Adjusting Injection Timing
76
Plunger Pressure Test
76
Delivery Valve Pressure Test
76
Adjusting Injection Volume (Uniformity of each Cylinder)
77
Measuring Injection Volume
77
Adjustment of Governor
77
Adjusting the Fuel Limit Bolt/Rpm Limit Bolt
77
Check the Injection Volume When Starting
78
Adjustment of Torque Rise
78
Models with Angleich Spring
78
Smoke Cut Spring
79
Automatic Advancing Timer
80
Timer Construction
80
Function and Characteristics of Timer
80
Timer Disassembly, Inspection and Reassembly
81
Fuel Feed Pump
82
Automatic Pressure Control Mechanism
82
Fuel Feed Pump Disassembly/Reassembly
82
Fuel Feed Pump Inspection
82
Fuel Feed Pump Adjustment
83
Adjustment of Fuel Injection Pump and Governor
84
Adjusting Injection Pipe
84
Nozzle Inspection
85
Fuel Injection Nozzle Reassembly
85
Fuel Filter Specifications
86
Fuel Filter Inspection
86
Intake and Exhaust System: Table of Contents
87
Turbocharger Specifications
88
Turbocharger Construction
88
Turbocharger Structure and Function
89
Interchangeability of Turbocharger Components
89
Interchangeability of Turbochargers
89
Turbocharger: Service Standards
90
Tightening Torque
91
Procedures for Periodical Checking of Turbocharger
91
Check of Rotor Rotation
91
Check of Rotor Play
92
Axial Play of Rotor
92
Cross Play of Rotor
92
Turbocharger Disassembly
93
Removal of Blower Housing
94
Removal of Blower Inpeller
94
Removal of Turbine Housing/Turbine Shaft/Seal Plate
94
Removal of Thrust Metal/Thrust Bush/Floating Metal/Seal Ring
94
Check before Cleaning Turbocharger
95
Turbocharger Cleaning Procedure
95
Turbocharger Checking Procedure
96
Turbocharger Reassembly Precedure
97
Assembly of Turbine Shaft/Fit Thrust Metal/Fit Seal Plate
98
Fit Blower Housing/Turbine Housing
98
Measure Rotor Play
98
Procedure for after Reassembly of Turbocharger
99
Turbocharger: Troubleshooting
100
Lubrication System: Table of Contents
101
Lubrication System
102
Lube Oil Pump Construction
103
Specifications of Lube Oil Pump
103
Lube Oil Pump Diagrams
104
Lube Oil Pump Removal
105
Lube Oil Pump Inspection
105
Lube Oil Pump Installation
105
Lube Oil Filter Construction
106
Lube Oil Filter Specifications
106
Lube Oil Filter Replacement
106
Oil Pressure Control Valve Construction
107
Oil Pressure Control Valve Replacement
107
Lube Oil Cooler Construction
108
Inspecting the Lube Oil Cooler
108
Piston Cooling Nozzle Construction
109
Inspection of Piston Cooling Nozzle
109
Rotary Waste Oil Pump Construction
110
Rotary Waste Oil Pump Inspection
110
Cooling Water System: Table of Contents
111
Cooling Water System Description and Diagram
112
Water Leakage Test (Fresh Water)
113
Removing Scale (During Disassembly)
113
Anti-Corrosion Agent
113
Antifreeze
113
Sea Water Pump Construction and Functioning
114
Parts List for Sea Water Pump
114
Spline Data
115
Sea Water Pump Disassembly
115
Sea Water Pump Inspection
115
Sea Water Pump Reassembly
115
Fresh Water Pump Conctruction
116
Parts List for Fresh Water Pump
116
Specifications of Fresh Water Pump
117
Fresh Water Pump Disassembly
117
Fresh Water Pump Inspection
117
Fresh Water Pump Diagram
117
Measuring Clearance between Impeller and Pump Body/Pump Body Bracket
118
Fresh Water Cooler Construction
119
Fresh Water Cooler Schematic Diagram
119
Specifications of Heat Exchanger
120
Disassembly and Reassembly of the Fresh Water Cooler
120
Pressure Cap Construction
121
Pressure Cap Pressure Control
121
Pressure Cap Inspection
121
Function of the Sub Tank
121
Specifications of Sub Tank
122
Mounting the Sub Tank
122
Precautions on Usage of the Sub Tank
122
Functioning of Thermostat
123
Thermostat Construction
123
Thermostat Characteristics
123
Thermostat Inspection
124
Thermostat Testing
124
Kingston Cock Construction/Inspection
125
Kingston Cock Handling Precautions
125
Reduction and Reversing Gear: Table of Contents
126
Reduction and Reversing Gear: Specification and System
127
Marine Gears (YANMAR MODEL: KMH6A)
127
Power Transmission
127
Reduction and Reversing Gear: Sectional View
128
Reduction and Reversing Gear: Hydraulic System
129
Reduction and Reversing Gear: Structure
129
Handling of Emergency Bolts
130
Service Standard
130
Wear Limit of Major Parts
130
Parts to be Replaced
130
Reassembly (KMH6A)
131
Disassembling Input and Output Gears
132
Disassembling Support Shafts a and B
132
Disassembling Valve Body
133
Cautions for Reassembly
134
Reassembly of Clutch
134
Shim Adjustment
135
Tightening Torque of Major Bolts
136
Standard Tightening Torque
136
Remote Control: Table of Contents
137
Construction of Remote Control System
138
Remote Control Device Components
138
Remote Control Installation
139
Speed Control
139
Ahead-Neutral-Astern Control
139
Electrical System: Table of Contents
140
System Diagram of Electric Parts
141
Battery Construction
142
Battery Capacity and Battery Cables
142
Battery Inspection
142
Checking the Electrolyte
143
Voltage Test
143
Washing the Battery
143
Charging Methods
144
Charging Procedure
144
Charging Precautions
144
Battery Storage Precautions
144
Starter Motor Specifications and Performance
145
Starter Motor Performance Curves
145
Starter Motor Features
145
Starter Motor Construction
146
Starter Motor Disassembly
147
Maintenance Standard for Starter Motor
149
Starter Motor Armature Inspection
150
Field Coil Continuity/Ground Test
151
Magnetic Switch
152
Starter Motor Reassembly Precautions
152
Starter Motor Adjustment and Performance Test
152
Starter Motor no Load Test
153
Starter Motor Troubleshooting
154
Alternator Features
155
Alternator Specifications
155
Characteristics
155
Alternator Construction
156
Alternator Functioning
157
Alternator Handling Precautions
157
Disassembling the Alternator
158
Alternator Inspection and Adjustment
159
Reassembling the Alternator
161
Alternator Performance Test
162
Alternator: Troubleshooting
163
Instrument Panel
165
Warning Devices
166
Oil Pressure Alarm
166
Cooling Water Temperature Alarm
167
Sender Unit for Lube Oil Pressure Gauge
167
Lube Oil Pressure Sender Unit
168
Sender Unit for the Cooling Water Temperature Gauge
168
Tachometer Construction
169
Specifications and Dimensions of Tachometer
169
Measurement of Sensor Unit Characteristics
170
Diagnosis
170
Disassembly and Reassembly
171
Disassembly and Reassembly Precautions
172
Disassembly and Reassembly Tools
173
Special Handtools
176
Measuring Instruments
178
Other Material
179
Disassembly
182
Drain Cooling Water
182
Removing (Electrical) Wiring/Fuel Oil Filter/Fuel Oil Pipe/Intake Silencercer
183
Removing the Mixing Elbow
183
Removing the Turbocharger
183
Removing the Intercooler
184
Removing the Starting Motor
185
Removing the Alternator
185
Removing the Cooling Water Pipe
185
Removing the Lube Oil Cooler/Fresh Water Tank/Fresh Water Cooler
186
Removing the Bonnet and Rocker Arm Assy
186
Removing the Fuel Injection Nozzle
186
Removing the Cylinder Head
186
Removing the Marine Gear/Front Pulley/Fresh Water Pump Pulley
187
Removing the Oil Pan/Intermediate for the Oil Pan
187
Removing Lube Oil Pump
187
Removing the Crank Shaft
187
Reassembly
188
Cylinder Block/Tappet/Piston Cooling Nozzle
188
Cam Shaft Bearing/Crankshaft
188
Fitting of Bearing Caps
189
Fitting of Lube Oil Pump Idle Gear
189
Measurement of Side Clearance
189
Fitting of Gear Case
190
Fitting of Cam Shaft
190
Insertion of Cylinder Sleeve
190
Piston Assembly
190
Lube Oil Intake Pipe and Delivery Pipe
191
Fitting of Oil Pan
191
Fitting of Flywheel Housing
191
Fitting of Seawater Pump
192
Fitting of Idle Gear
192
Fitting of Oil Pressure Regulating Valve
192
Fitting of Cooling Water Passage Cover/Injection Pump
192
Fitting of Oil Seal
193
Fitting of Flywheel
193
Cylinder Head Assembly
193
Fitting of Head Gasket
193
Fitting of Turbine Cooling Fresh Water (CWF) Pipe
194
Fitting of Intercooler
194
Intake Manifold Assembly
194
Fitting of Marine Gear
194
Push Rod, Valve Arm Shaft Assembly
195
Rocker Arm Shaft Assembly
195
Fresh Water Pump Assembly
195
Gear Case Cover
195
Localizing of Gear Train
196
Crank V-Pulley
196
Fuel Injection Valve
196
Fitting of Fresh Water Tank
197
Fitting of Fresh Water Cooler
197
Installation of Lube Oil Cooler
197
Cooling Water Bend
198
Air Duct
198
Intercooler Steady Brace/Boost Output Pipe
198
Lube Oil Cooler Assembly
198
Installation of Turbocharger
199
Mixing Elbow/Lube Oil Pipe
199
Alternator
199
Starting Motor
199
Fitting of Cooler Water Pipe
200
Driving of Dipstick Guide
200
Bolt/Nut Tightening Torque
201
Main Bolt and Nut Tightening Torque
201
General Tightening Torque (Without Lubricant)
201
Quality Control Table
202
Assembly Quality (Clearance, Interference) Table
205
Test Running
207
Preliminary Precautions
207
Check Points and Precautions During Running
207
Troubleshooting
209

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