Yanmar MARINE DIESEL ENGINE 6SY-STP2, 6SY655, 6SY-STP Service Repair Manual
Complete service repair manual with Electrical Wiring Diagrams for Yanmar MARINE DIESEL ENGINE SY-series (6SY-STP2, 6SY655, 6SY-STP), with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Yanmar MARINE DIESEL ENGINE SY-series (6SY-STP2, 6SY655, 6SY-STP) workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 278 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
0BSYM-G00100 - Yanmar MARINE DIESEL ENGINE SY-series (6SY-STP2, 6SY655, 6SY-STP) Service Manual.pdf
MAIN SECTIONS
6SY / 8SY Service Manual
Table of Contents ... 2-1
Introduction ... 1-1
Safety... 2-1
General Service Information ... 3-1
Periodic Maintenance ... 4-1
Engine ... 5-1
Fuel System ... 6-1
Cooling System ... 7-1
Lubrication... 8-1
Turbocharger ... 9-1
Starter Motor... 10-1
Alternator ... 11-1
EMS... 12-1
Troubleshooting ... 13-1
Table of Contents
Revision History...6
Revision Control Table...6
Safety Precautions...8
Safety Precautions...15
Engine Outline Drawings...16
6SY-STP2 X ZF325-1...16
8SY-STP X MG5114 IV...17
Engine Piping Diagrams...18
Location of Nameplates...21
Engine Nameplate (Typical)...21
Diesel Fuel...22
Diesel Fuel Specifications...22
Additional Technical Fuel Requirements...22
Diesel Fuel Lines...22
Filling the Fuel Tank...23
Bleeding the Fuel System...23
Engine Oil...24
Engine Oil Specifications ...24
Service Categories...24
Definitions...24
Additional Technical Engine Oil Requirements:...24
Engine Oil Viscosity...24
Maximum Angles of Inclination During Operation...25
Selection of Marine Gear Oil...25
Engine Coolant...25
Engine Coolant Specifications...25
Coolant (Closed Cooling System)...25
Principal Engine Specifications...27
Engine Service Standards...29
Tightening Torques for Standard Bolts and Nuts...30
Tightening Fasteners...30
Abbreviations and Symbols...31
Abbreviations...31
Symbols...31
Unit Conversions...32
Unit Prefixes...32
Units of Length...32
Units of Volume...32
Units of Mass...32
Units of Force...32
Units of Torque...32
Units of Pressure...32
Units of Power...32
Units of Temperature...32
Introduction...35
The Importance of Periodic Maintenance...35
Performing Periodic Maintenance...35
Yanmar Replacement Parts...35
Required EPA Maintenance - USA Only...35
EPA Installation Requirements - USA Only...35
Periodic Maintenance Schedule...36
Inspection and Maintenance of EPA Emission-Related Parts...38
Periodic Maintenance Procedures...39
<TABLE>...39
<TABLE>...39
<TABLE>...40
<TABLE>...40
<TABLE>...41
<TABLE>...41
EPA Requirements...42
Conditions to Ensure Compliance with EPA Emission Standards...42
Inspection and Maintenance...42
Safety Precautions...45
Introduction...46
Principal Engine Specifications...46
Adjustment Specifications...46
Cylinder Head Specifications...47
Cylinder Head and Valves...47
Camshaft and Timing Gear Train Specifications...48
Camshaft...48
Intermediate Gear and Bushing...48
Timing Gear Backlash...48
Crankshaft and Pistons Specifications...49
Crankshaft...49
Thrust Bearing...49
Cylinder Liner...50
Connecting Rod...50
Piston Ring...50
Special Torque Chart...51
Special Service Tools...53
Measuring Instruments...58
Tests and Adjustments...60
Adjust Valve and Unit Injector Clearances...60
Adjusting Unit Injectors...61
Digital Caliper Method:...62
Special Tool Method:...62
Repair...63
Cylinder Head...64
Cylinder Head Components...64
General Guidelines...65
Remove and Install Rocker Covers...65
Upper Rocker Cover...65
Lower Rocker Cover...66
Remove the Cylinder Head...68
Disassemble the Cylinder Head...69
Clean the Cylinder Head Components...69
Inspect the Cylinder Head Components...69
Inspection of Intake and Exhaust Valves...69
Replace the Valve Stem Seals...71
Replace the Valve Seat...71
Removal...71
Machine the Valves...72
Machine the Valve Seat Inserts...72
Specifications...72
Procedure...73
Replace the Valve Guides...75
Replace the Unit Injector Sleeves...75
Reassemble the Cylinder Head...76
Install the Cylinder Head...76
Pistons and Cylinder Liners...78
Remove and Disassemble Piston and Connecting Rod...79
Inspect the Connecting Rods...80
Replace the Wrist Pin Bushing...82
Inspect the Pistons and Piston Rings...83
Assemble the Piston and Connecting Rod...83
Remove the Cylinder Liners...84
Measure the Cylinder Liner Height...86
Install the Cylinder Liners...86
Install the Piston and Connecting Rod...87
Flywheel and Flywheel Housing...90
Flywheel Housing Components - 6SY Engines...90
Flywheel Housing Components - 8SY Engines...92
Remove the Flywheel...93
Flywheel Inspection and Repair...94
Support Bearing Replacement...94
Remove the Ring Gear...94
Replace the Rear Crankshaft Seal...94
Remove the Flywheel Housing ...95
Install the Flywheel Housing...95
Install the Flywheel...96
Timing Gear Train...98
6SY Components...98
8SY Components...100
Check the Camshaft Timing...102
6SY Engines...102
8SY Engines...102
Remove the Front Gear Housing - 8SY...102
Install the Front Gear Housing - 8SY...104
Intermediate Gear...104
Remove...104
Bearing Replacement - 6SY...106
Bearing Replacement - 8SY...107
Intermediate Gear Installation...108
Camshaft Gear...109
Remove...109
Install...110
Crankshaft Gear...111
Remove...111
Install...111
Remove the Camshaft...112
Replace the Camshaft Bearings - 6SY...113
Replace the Camshaft Bearings - 8SY...117
Install the Camshaft...120
Cylinder Block and Crankshaft...124
Remove the Crankshaft...126
Measure the Oil Clearance...127
Inspect the Crankshaft...128
Recondition the Crankshaft...129
Checking and Grinding...129
Inspect the Cylinder Block...129
Reconditioning...129
Install Crankshaft...130
Replace the Front Crankshaft Seal...132
Exhaust Manifold...133
Replacing Gaskets...133
Make sure that all connections are tightened to specifications after repair is made to the exhaust system. ...133
Lifting the Engine...134
6SY Engines...134
8SY Engines...134
Attaching Engine to Repair Stand...135
Safety Precautions...139
Introduction...139
Specifications...140
Special Service Tools...141
Fuel System Components...142
Fuel Delivery Components...142
Fuel Injector Components...143
Tests and Adjustments...143
Adjust the Unit Injectors...143
Measure the Fuel Feed Pump Pressure...143
Procedure...143
Results...144
Test the Fuel Pressure Relief Valve...144
Procedure...144
Results...144
Repair...144
Remove the Unit Injector...144
Install the Unit Injector...147
Replace the Fuel Feed Pump...149
If the fuel feed pump refuses to prime:...150
Replace the Fuel Filter and Fuel Filter / Water Separator...150
Replace the Fuel Filter...150
Replace the Fuel Filter / Water Separator...151
Replace Return Fuel Line...151
6SY Engines...152
8SY Engines...153
Bleed the Fuel System...153
If the engine fails to start after bleeding:...154
Introduction...157
Specifications...158
Special Service Tools...159
Measuring instruments...160
Tests and Adjustments...161
Pressure Testing Cooling System and Filler Cap...161
Cooling System...161
Filler Cap...161
Testing the Thermostat...162
Repair...162
Drain, Flush and Fill the Engine with Engine Coolant...162
Venting the Cooling System - 8SY Engines Only...163
Coolant Pump Removal...164
Install Coolant Pump...165
Remove and Install Pulley...165
Change the Coolant Pump Seal...166
Remove and Install Thermostat...168
6SY Thermostat Removal...168
Thermostat Removal - 8SY...169
Thermostat Installation - All Engines...169
Remove and Install Fresh Water Charge Air Cooler...169
Remove and Install Seawater Charge Air Cooler - 6SY Engines Only...172
Remove and Install the Heat Exchanger...174
6SY Engines...174
8SY Engines...176
Seawater Pump...178
Replace the Impeller...178
Remove and Disassemble Seawater Pump...179
Inspect the Seawater Pump...180
Assemble the Seawater Pump...181
Check or Replace the Zinc Anodes...182
Introduction...187
Specifications...187
Special Service Tools...188
Tests and Adjustments...189
Check the Engine Oil Pressure...189
Repair...190
Remove and Install the Oil Cooler...190
6SY Engines...190
8SY Engines...191
Remove and Install Oil Cleaning Components...193
Replace the Engine Oil Filter - 8SY...195
Clean the Centrifugal Engine Oil Cleaner...195
Oil Pump...198
Removal of Oil Pump...199
Installation of Oil Pump...199
Introduction...203
General Information...203
Oil Leaks...203
Foreign Bodies...203
Air and Exhaust Leaks...203
Oil Filter...203
Cleaning the Compressor Wheel...203
Specifications...204
Special Service Tools...205
Component Location...206
6SY Engines...206
8SY Engines...207
Tests and Adjustments...208
Measuring Charge Pressure...208
Repair...208
If the Turbocharger Does Not Operate:...208
Remove Turbocharger...209
Inspect the Turbocharger...210
Cleaning the Compressor...210
Measure the Radial and Axial Clearance...210
Radial Clearance...211
Axial Clearance...211
Install the Turbocharger...212
Before You Begin Servicing...217
Introduction...218
Starter Motor Specifications...219
Starter Motor Troubleshooting...220
Remove and Install Starter Motor...221
Repair Starter Motor - Bosch JE...222
Components...222
Brush Replacement...224
Equipment Required...224
Repair...224
Replace Solenoid...225
Before You Begin Servicing...229
Introduction...230
Specifications...231
Calculating Alternator Capacity...232
Alternator and Charging System Troubleshooting...232
Test and Inspection...233
Output Test...233
Brush Length...234
Rotor...234
Slip Rings...234
Resistance...234
Repair...235
Replace Alternator Belt...235
Introduction...239
Specifications...239
Specifications...239
Special Service Tools...239
Function Description - Engine Management System (EMS S6)...240
General...240
Component Location...241
6SY Engines...241
8SY Engines...242
Engine Speed Sensors - T28 and T29...243
Charge Air Pressure and Temperature Sensor - T26...244
Charge Air Pressure Sensor...245
Charge Air Temperature Sensor...245
Coolant Temperature Sensor - T27...246
Oil Pressure Sensor - T25...247
EMS S6 Control Unit E44...248
Function of EMS S6 Control Unit...248
EMS S6 Control Unit Connections...249
EMS S6 Control Unit Pin Assignments...250
Repair...253
Replace the EMS S6 Control Unit...253
6SY Engines...253
Remove the EMS S6 Wiring...253
Installing EMS S6 Wiring...256
Wiring and Cable Duct - 6SY...256
Introduction...263
Troubleshooting Chart...263
Fault Codes...278
Working Procedure...278
After Troubleshooting or Repair...278
