Yanmar 6LY2-STE/6LY2A-STP/6LYA-STP Marine Diesel Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the 6LY2-STE, 6LY2A-STP & 6LYA-STP Yanmar Marine Diesel Engine has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

Yanmar 6LY2-STE
Yanmar 6LY2A-STP
Yanmar 6LYA-STP


TABLE OF CONTENTS :

CHAPTER 1.GENERAL
CHAPTER 2.INSPECTION AND SERVICING OF BASIC ENGINE PARTS
CHAPTER 3.FUEL INJECTION EQUIPMENT
CHAPTER 4.TURBOCHARGER SYSTEM
CHAPTER 5.LUBRICATION SYSTEM
CHAPTER 6.COOLING WATER SYSTEM
CHAPTER 7.REDUCTION AND REVERSING GEAR
CHAPTER 8.REMOTO CONTROL(OPTIONAL)
CHAPTER 9.ELECTRICAL SYSTEM
CHAPTER 10.DISASSEMBLY AND REASSEMBLY
CHAPTER 11.TROUBLESHOOTING


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Code No. : HINSI-H8-011-1
Total Pages : 234


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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COVER
FOREWORD
INDEX
CHAPTER 1.GENERAL
1.Exterior Views
2.Specifications
3.Performance Curves
4.Dimensions
5.Wiring Diagrams
6.Piping Diagrams
CHAPTER 2.INSPECTION AND SERVICING OF BASIC ENGINE PARTS
1.Cylinder Block
1-1.Inspection of parts
1-2.Cleaning of oil holes
1-3.Color check procedure
1-4.Replacement of cup plugs
1-5.Cylinder bore measurement
2.Cylinder Head
2-1.Inspecting the cylinder head
2-2.Valve seat correction procedure
2-3.Intake/exhaust valves,valve guides
2-4.Valve springs
2-5.Assembling the cylinder head
2-6.Measuring top clearance
2-7.Intake and exhaust valve arms
2-8.Adjustment of valve clearance
2-9.Checking and adjusting the fuel injection timing
3.Piston and Piston Pins
3-1.Piston
3-2.Piston Pin
3-3.Piston rings
4.Connecting Rod
4-1.Inspecting the connection rod
4-2.Crank pin bearing
4-3.Piston pin bearing
4-4.Assembling piston and connecting rod
5.Crankshaft and Main Bearing
5-1.Crankshaft
5-2.Main bearing
6.Camshaft and Tappets
6-1.Camshaft
6-2.Tappets
7.Timing Gear
7-1.Inspecting the gears
7-2.Gear timing marks
8.Flywheel
8-1.Specifications of flywheel
8-2.Dimensions of flywheel and mounting flange
8-3.Ring gear
8-4.Position of top dead center and fuel injection timing
CHAPTER 3.FUEL INJECTION EQUIPMENT
1.Fuel injection Pump Construction
2.Fuel injection pump Specifications
3.Fuel supply System
3-1.Fuel supply system
3-2.Functioning of fuel injection pump
3-3.Injection volume control
3-4.Governor construction
3-5.Types of governor according to structure
3-6.Idling and Maximum speed
4.Fuel Injection Nozzle
4-1.Functioning of fuel injection nozzle
4-2.Fuel injection nozzle disassembly
4-3.Fuel injection nozzle inspection
4-4.Adjusting fuel injection nozzle
5.Fuel Feed Pump
6.Disassembly, Reassembly and Inspection of Governor
6-1.Governor disassembly
6-2.Inspection of governor
6-3.Assembling the governor
7.Disasembly,Reassembly and Inspection of Fuel injection pump
7-1.Disassembly of fuel injection pump
7-2.Inspection of fuel injection pump
7-3.Reassembly of fuel injection pump
7-4.Adjustment of Pre-stroke
7-5.Adjusting injection timing
7-6.Plunger pressure test
7-7.Delivery valve pressure test
7-8.Adjusting injection volume(uniformity of each cylinder)
7-9.Adjustment of governor
7-10.Adjustment of torque rise
8.Automatic Advancing Timer
8-1.Timer construction
8-2.Function and characteristics of timer
8-3.Timer disassembly
8-4.Timer inspection
8-5.Timer reassembly
9.Fuel feed pump
9-1.Fuel Feed Pump Disassembly
9-2.Fuel Feed Pump Inspection
9-3.Fuel Feed Pump Reassembly
9-4.Fuel Feed Pump Adjustment
10.Adjustment of Fuel Injection Pump and Governor
10-1.Preparations
10-2.Nozzle inspection
10-3.Fuel injection nozzle reassembly
11.Fuel Filter
11-1.Fuel filter specifications
11-2.Fuel filter inspection
CHAPTER 4.TURBOCHARGER SYSTEM
1.Construction and Function
1-1.Outline
2.Standards for Maintenance and Check
2-1.Standards for Maintenance and Check
2-2.Tightening Torque
3.Periodical Checking Procedure
3-1.Periodical Checking Interval
3-2.Checking Procedure
4.Disassembly Procedure
4-1.Preparations for Disassembly
4-2.Check before Disassembly
4-3.Disassembly
5.Cleaning and Checking Procedure
5-1.Cleaning
5-2.Checking Procedure
6.Reassembling procedure
6-1.Preparations for Reassembly
6-2.Reassembling procedure
7.Handling After Reassembly
7-1.Precautions for mounting the turbocharger to the engine
8.Troubleshooting
8-1.Exhaust gas is dense
8-2.Whitish exhaust gas
8-3.Too early oil shortage
8-4.Output drop
8-5.Poor follow-up of supercharger
8-6.Unusual sound or vibration
CHAPTER 5.LUBRICATION SYSTEM
1.Lubrication System
2.Lube Oil Pump
2-1.Lube oil pump construction
2-2.Specifications of lube oil pump
2-3.Removal
2-4.Inspection
2-5.Instllation
3.Lube Oil Filter
3-1.Lube oil filter construction
3-2.Lube oil filter replacement
4.Oil Pressure Control Valve
4-1.Oil pressure control valve construction
4-2.Oil pressure control valve replacement
5.Lube Oil Cooler
5-1.Lube oil cooler construction
5-2.Inspecting the lube oil cooler
6.Piston Cooling Nozzle
6-1.Piston cooling nozzle construction
6-2.Inspection of piston cooling nozzle
7.Rotary Waste Oil Pump(Optional)
7-1.Construction
7-2.Inspection the waste oil pump
CHAPTER 6.COOLING WATER SYSTEM
1.Cooling Water System
1-1.System
1-2.Water leakage test(Fresh water)
1-3.Removing Scale(During Disassembly)
1-4.Anti-Corrosion Agent
1-5.Antifreeze
2.Sea Water Pump
2-1.Sea water pump construction and functioning
2-2.Sea water pump disassembly
2-3.Sea water pump inspection
2-4.Sea water pump reassembly
3.Fresh Water Pump
3-1.Fresh water pump construction
3-2.Specifications of fresh water pump
3-3.Fresh water pump disassembly
3-4.Fresh water pump reassembly
4.Fresh Water Cooler
4-1.Fresh water cooler construction
4-2.Specifications of heat exchanger
4-3.Disassembly and reassembly of the fresh water cooler
4-4.Fresh water cooler inspection
5.Pressure Cap and Sub Tank
5-1.Pressure cap construction
5-2.Pressure cap pressure control
5-3.Pressure cap inspection
5-4.Function of the sub tank
5-5.Specifications of sub tank
5-6.Mounting the sub tank
5-7.Precautions on usage of the sub tank
6.Thermostat
6-1.Functioning of thermostat
6-2.Thermostat construction
6-3.Characteristics of thermostat
6-4.Thermostat inspection
6-5.Testing the thermostat
7.Kingston Cock(Optional)
7-1.Construction
7-2.Handling precautions
7-3.Inspection
CHAPTER 7.REDUCTION AND REVERSING GEAR
1.Specification and System
1-1.Marine Gears(YANMAR MODEL KMH6A1)
2.Readdembly and disassembly(KMH6A1)
2-1.Disassembly
2-2.Disassembling input and output gears
2-3.Disassembling support shafts A and B
2-4.Disassembling valve body
3.Cautions for Reassembly
3-1.Cautions for Reassembly
3-2.Tightening Torque of Major Bolts
3-3.Standerd Tightening Torque
CHAPTER 8.REMOTO CONTROL(OPTIONAL)
1.Remoto Control System(Option)
1-1.Construction of remoto control system
1-2.Remoto control device components
2.Remoto Control Installation
2-1.Speed control
2-2.Ahead-neutral-astern control
CHAPTER 9.ELECTRICAL SYSTEM
1.System Diagram
1-1.System diagram of electric parts
2.Battery
2-1.Construnctlon
2-2.Battery capacity and battery cables
2-3.Inspection
2-4.Charging
2-5.Battery storage precautions
3.Starter Motor
3-1.Specifications and Performance
3-2.Features
3-3.Construction
3-4.Disassembly
3-5.Maintenance standerd
3-6.Inspection
3-7.Reassembly precautions
3-8.Adjustment and performance test
3-9.Testing
3-10.Troubleshooting
4.Alternator
4-1.Features
4-2.Specifications
4-3.Characteristics
4-4.Construction
4-5.Alternator functioning
4-6.Handling precautions
4-7.Disassembling the alternator
4-8.Inspection and adjustment
4-9.Reassembling the alternator
4-10.Performamce test
4-11.Troubleshooting
5.Instrument Panel
6.Warning Devices
6-1.Oil pressure alarm
6-2.Cooling water temperature alarm
6-3.Sender unit for lube pressure gauge
6-4.Sender unit for the cooling water temperature gauge
7.Tachometer
7-1.Construction of tachometer
7-2.Specifications and dimensions of tachometer
7-3.Measurement of sensor unit characteristics
7-4.Diagnosis
CHAPTER 10.DISASSEMBLY AND REASSEMBLY
1.Disassembly and Reassembly precautions
2.Disassembly and Reassembly Tools
2-1.Special Handtools
2-2.Measuring Instruments
2-3.Other material
3.Disassembly and Reassembly
3-1.Disassembly
3-2.Reassembly
4.Main parts spec./ tightening torque
4-1.Quality control points
4-2.Dimension of Main Parts
4-3.Bolt/Nut Tightening torque
5.Test running
5-1.Preliminary Precautions
5-2.Check Points and Precautions During Running
CHAPTER 11.TROUBLESHOOTING
1.Troubleshooting
BACK COVER

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