Yanmar 6LYA-STE - Installation of Turbocharger; Mixing Elbow;Lube Oil Pipe; Alternator; Starting Motor

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Index4
General Information5
Exterior Views: Non-Operating Side/Operating Side6
Specifications/Engine7
Performance Curves 6LYA-UTE8
Performance Curves 6LYA-STE9
Dimensions10
With KMH6A Marine Gear Diagrams11
Wiring Diagrams12
New B-Type Instrument Panel Diagram12
New C-Type Instrument Panel Diagram13
New D-Type Instrument Panel Diagram14
Piping Diagrams15
Inspection and Servicing of Basic Engine Parts16
Cylinder Block17
Cleaning of Oil Holes17
Color Check Procedure17
Replacement of Cup Plugs18
Cylinder Bore Measurement19
Cylinder Sleeve20
Measurement of Sleeve20
Insertion of Cylinder Sleeve20
Measurement of Projection20
Cylinder Head21
Inspecting the Cylinder Head22
Distortion of the Combustion Surface22
Checking for Cracks in the Combustion Surface22
Checking the Intake and Exhaust Valve Seats22
Valve Seat Correction Procedure23
Wearing and Corrosion of Valve Stem23
Intake/Exhaust Valves, Valve Guides23
Inspection of Valve Seat Wear and Contact Surface24
Valve Sinking24
Valve Stem Seals25
Checking Valve Springs25
Measure Spring Tension25
Spring Retainer and Spring Cotter25
Assembling the Cylinder Head26
Measuring Top Clearance26
Intake and Exhaust Valve Arms26
Adjustment of Valve Clearance27
Checking and Adjusting the Fuel Injection Timing28
Vale Opening Diagram28
Piston and Piston Pins29
Piston Head and Combustion Surface29
Measurement of Piston Outside Diameter/Inspection29
Replacing the Piston30
Piston Pin/Piston Rings30
Measuring the Rings30
Measuring Piston Ring Gap31
Replacing the Piston Rings31
Inspecting the Connection Rod33
Crank Pin Bearing34
Inspecting Piston Pin Bearing34
Assembling Piston and Connecting Rod35
Crankshaft and Main Bearing36
Crankshaft36
Bending of the Crankshaft37
Measuring the Crank Pin and Journal37
Checking Side Clearance of the Crankshaft38
Main Bearing38
Camshaft39
Tappets40
Timing Gear42
Flywheel44
Dimensions of Flywheel and Mounting Flange45
Ring Gear46
Position of Top Dead Center and Fuel Injection Timing46
Fuel Injection Equipment. Table of Contents47
Fuel Injection Pump Construction48
Fuel Injection Pump Specifications49
Fuel Supply System50
Functioning of Fuel Injection Pump50
Injection Volume Control51
Full Injection Volume Position51
Half Injection Volume Position51
No Fuel Injection51
Governor Construction52
Types of Governor According to Structure53
Shape of Control and Stop Levers/Engine Stop Device53
Torque Rise Equipment53
Smoke Cut Device53
Boost Compensator54
Objective of Compensator54
Outline of Structure and Principle of Operation54
Operation of Cancel Knob55
Adjustment of Boost Compensator55
Idling and Maximum Speed56
Adjustment of Fuel Injection Timing56
Functioning of Fuel Injection Nozzle57
Hole Type Fuel Injection Nozzle Diagram57
Fuel Injection Nozzle Disassembly58
Fuel Injection Nozzle Inspection58
Adjusting Fuel Injection Nozzle59
Adjusting Opening Pressure59
Injection Test59
Fuel Feed Pump Design and Function60
Disassembly, Reassembly and Inspection of Governor61
Governor Disassembly62
Inspection of Governor Weight Assembly63
Inspection of Governor Sleeve64
Inspection of Governor Lever Assembly64
Inspection of Springs64
Inspection of Torque Spring Assembly64
Assembling the Governor65
Disassembly, Reassembly and Inspection of Fuel Injection Pump67
Disassembly of Fuel Injection Pump68
Inspection of Fuel Injection Pump71
Reassembly of Fuel Injection Pump72
Adjustment of Pre-Stroke75
Adjusting Injection Timing76
Plunger Pressure Test76
Delivery Valve Pressure Test76
Adjusting Injection Volume (Uniformity of each Cylinder)77
Measuring Injection Volume77
Adjustment of Governor77
Adjusting the Fuel Limit Bolt/Rpm Limit Bolt77
Check the Injection Volume When Starting78
Adjustment of Torque Rise78
Models with Angleich Spring78
Smoke Cut Spring79
Automatic Advancing Timer80
Timer Construction80
Function and Characteristics of Timer80
Timer Disassembly, Inspection and Reassembly81
Fuel Feed Pump82
Automatic Pressure Control Mechanism82
Fuel Feed Pump Disassembly/Reassembly82
Fuel Feed Pump Inspection82
Fuel Feed Pump Adjustment83
Adjustment of Fuel Injection Pump and Governor84
Adjusting Injection Pipe84
Nozzle Inspection85
Fuel Injection Nozzle Reassembly85
Fuel Filter Specifications86
Fuel Filter Inspection86
Intake and Exhaust System: Table of Contents87
Turbocharger Specifications88
Turbocharger Construction88
Turbocharger Structure and Function89
Interchangeability of Turbocharger Components89
Interchangeability of Turbochargers89
Turbocharger: Service Standards90
Tightening Torque91
Procedures for Periodical Checking of Turbocharger91
Check of Rotor Rotation91
Check of Rotor Play92
Axial Play of Rotor92
Cross Play of Rotor92
Turbocharger Disassembly93
Removal of Blower Housing94
Removal of Blower Inpeller94
Removal of Turbine Housing/Turbine Shaft/Seal Plate94
Removal of Thrust Metal/Thrust Bush/Floating Metal/Seal Ring94
Check before Cleaning Turbocharger95
Turbocharger Cleaning Procedure95
Turbocharger Checking Procedure96
Turbocharger Reassembly Precedure97
Assembly of Turbine Shaft/Fit Thrust Metal/Fit Seal Plate98
Fit Blower Housing/Turbine Housing98
Measure Rotor Play98
Procedure for after Reassembly of Turbocharger99
Turbocharger: Troubleshooting100
Lubrication System: Table of Contents101
Lubrication System102
Lube Oil Pump Construction103
Specifications of Lube Oil Pump103
Lube Oil Pump Diagrams104
Lube Oil Pump Removal105
Lube Oil Pump Inspection105
Lube Oil Pump Installation105
Lube Oil Filter Construction106
Lube Oil Filter Specifications106
Lube Oil Filter Replacement106
Oil Pressure Control Valve Construction107
Oil Pressure Control Valve Replacement107
Lube Oil Cooler Construction108
Inspecting the Lube Oil Cooler108
Piston Cooling Nozzle Construction109
Inspection of Piston Cooling Nozzle109
Rotary Waste Oil Pump Construction110
Rotary Waste Oil Pump Inspection110
Cooling Water System: Table of Contents111
Cooling Water System Description and Diagram112
Water Leakage Test (Fresh Water)113
Removing Scale (During Disassembly)113
Anti-Corrosion Agent113
Antifreeze113
Sea Water Pump Construction and Functioning114
Parts List for Sea Water Pump114
Spline Data115
Sea Water Pump Disassembly115
Sea Water Pump Inspection115
Sea Water Pump Reassembly115
Fresh Water Pump Conctruction116
Parts List for Fresh Water Pump116
Specifications of Fresh Water Pump117
Fresh Water Pump Disassembly117
Fresh Water Pump Inspection117
Fresh Water Pump Diagram117
Measuring Clearance between Impeller and Pump Body/Pump Body Bracket118
Fresh Water Cooler Construction119
Fresh Water Cooler Schematic Diagram119
Specifications of Heat Exchanger120
Disassembly and Reassembly of the Fresh Water Cooler120
Pressure Cap Construction121
Pressure Cap Pressure Control121
Pressure Cap Inspection121
Function of the Sub Tank121
Specifications of Sub Tank122
Mounting the Sub Tank122
Precautions on Usage of the Sub Tank122
Functioning of Thermostat123
Thermostat Construction123
Thermostat Characteristics123
Thermostat Inspection124
Thermostat Testing124
Kingston Cock Construction/Inspection125
Kingston Cock Handling Precautions125
Reduction and Reversing Gear: Table of Contents126
Reduction and Reversing Gear: Specification and System127
Marine Gears (YANMAR MODEL: KMH6A)127
Power Transmission127
Reduction and Reversing Gear: Sectional View128
Reduction and Reversing Gear: Hydraulic System129
Reduction and Reversing Gear: Structure129
Handling of Emergency Bolts130
Service Standard130
Wear Limit of Major Parts130
Parts to be Replaced130
Reassembly (KMH6A)131
Disassembling Input and Output Gears132
Disassembling Support Shafts a and B132
Disassembling Valve Body133
Cautions for Reassembly134
Reassembly of Clutch134
Shim Adjustment135
Tightening Torque of Major Bolts136
Standard Tightening Torque136
Remote Control: Table of Contents137
Construction of Remote Control System138
Remote Control Device Components138
Remote Control Installation139
Speed Control139
Ahead-Neutral-Astern Control139
Electrical System: Table of Contents140
System Diagram of Electric Parts141
Battery Construction142
Battery Capacity and Battery Cables142
Battery Inspection142
Checking the Electrolyte143
Voltage Test143
Washing the Battery143
Charging Methods144
Charging Procedure144
Charging Precautions144
Battery Storage Precautions144
Starter Motor Specifications and Performance145
Starter Motor Performance Curves145
Starter Motor Features145
Starter Motor Construction146
Starter Motor Disassembly147
Maintenance Standard for Starter Motor149
Starter Motor Armature Inspection150
Field Coil Continuity/Ground Test151
Magnetic Switch152
Starter Motor Reassembly Precautions152
Starter Motor Adjustment and Performance Test152
Starter Motor no Load Test153
Starter Motor Troubleshooting154
Alternator Features155
Alternator Specifications155
Characteristics155
Alternator Construction156
Alternator Functioning157
Alternator Handling Precautions157
Disassembling the Alternator158
Alternator Inspection and Adjustment159
Reassembling the Alternator161
Alternator Performance Test162
Alternator: Troubleshooting163
Instrument Panel165
Warning Devices166
Oil Pressure Alarm166
Cooling Water Temperature Alarm167
Sender Unit for Lube Oil Pressure Gauge167
Lube Oil Pressure Sender Unit168
Sender Unit for the Cooling Water Temperature Gauge168
Tachometer Construction169
Specifications and Dimensions of Tachometer169
Measurement of Sensor Unit Characteristics170
Diagnosis170
Disassembly and Reassembly171
Disassembly and Reassembly Precautions172
Disassembly and Reassembly Tools173
Special Handtools176
Measuring Instruments178
Other Material179
Disassembly182
Drain Cooling Water182
Removing (Electrical) Wiring/Fuel Oil Filter/Fuel Oil Pipe/Intake Silencercer183
Removing the Mixing Elbow183
Removing the Turbocharger183
Removing the Intercooler184
Removing the Starting Motor185
Removing the Alternator185
Removing the Cooling Water Pipe185
Removing the Lube Oil Cooler/Fresh Water Tank/Fresh Water Cooler186
Removing the Bonnet and Rocker Arm Assy186
Removing the Fuel Injection Nozzle186
Removing the Cylinder Head186
Removing the Marine Gear/Front Pulley/Fresh Water Pump Pulley187
Removing the Oil Pan/Intermediate for the Oil Pan187
Removing Lube Oil Pump187
Removing the Crank Shaft187
Reassembly188
Cylinder Block/Tappet/Piston Cooling Nozzle188
Cam Shaft Bearing/Crankshaft188
Fitting of Bearing Caps189
Fitting of Lube Oil Pump Idle Gear189
Measurement of Side Clearance189
Fitting of Gear Case190
Fitting of Cam Shaft190
Insertion of Cylinder Sleeve190
Piston Assembly190
Lube Oil Intake Pipe and Delivery Pipe191
Fitting of Oil Pan191
Fitting of Flywheel Housing191
Fitting of Seawater Pump192
Fitting of Idle Gear192
Fitting of Oil Pressure Regulating Valve192
Fitting of Cooling Water Passage Cover/Injection Pump192
Fitting of Oil Seal193
Fitting of Flywheel193
Cylinder Head Assembly193
Fitting of Head Gasket193
Fitting of Turbine Cooling Fresh Water (CWF) Pipe194
Fitting of Intercooler194
Intake Manifold Assembly194
Fitting of Marine Gear194
Push Rod, Valve Arm Shaft Assembly195
Rocker Arm Shaft Assembly195
Fresh Water Pump Assembly195
Gear Case Cover195
Localizing of Gear Train196
Crank V-Pulley196
Fuel Injection Valve196
Fitting of Fresh Water Tank197
Fitting of Fresh Water Cooler197
Installation of Lube Oil Cooler197
Cooling Water Bend198
Air Duct198
Intercooler Steady Brace/Boost Output Pipe198
Lube Oil Cooler Assembly198
Installation of Turbocharger199
Mixing Elbow/Lube Oil Pipe199
Alternator199
Starting Motor199
Fitting of Cooler Water Pipe200
Driving of Dipstick Guide200
Bolt/Nut Tightening Torque201
Main Bolt and Nut Tightening Torque201
General Tightening Torque (Without Lubricant)201
Quality Control Table202
Assembly Quality (Clearance, Interference) Table205
Test Running207
Preliminary Precautions207
Check Points and Precautions During Running207
Troubleshooting209

Yanmar 6LYA-STE - Installation of Turbocharger; Mixing Elbow;Lube Oil Pipe; Alternator; Starting Motor

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