Yanmar SY Series Marine Diesel Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the Series SY 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 Marine Diesel Engine 6SY-STP2
Yanmar Marine Diesel Engine 6SY655
Yanmar Marine Diesel Engine 8SY-STP

6SY-STP : Yanmar Inboard Engine 720hp/530kW - EPB5669
8SY-STP : Yanmar Inboard Engine 900hp/663kW - EPB5669


TABLE OF CONTENTS :

Introduction
Safety
General Service Information
Periodic Maintenance
Engine
Fuel System
Cooling System
Lubrication
Turbocharger
Starter Motor
Alternator
EMS
Troubleshooting


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : OBSYM-G00100
Total Pages : 279


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
Revision History
Revision Control Table
Safety Precautions
Safety Precautions
Engine Outline Drawings
6SY-STP2 X ZF325-1
8SY-STP X MG5114 IV
Engine Piping Diagrams
Location of Nameplates
Engine Nameplate (Typical)
Diesel Fuel
Diesel Fuel Specifications
Additional Technical Fuel Requirements
Diesel Fuel Lines
Filling the Fuel Tank
Bleeding the Fuel System
Engine Oil
Engine Oil Specifications
Service Categories
Definitions
Additional Technical Engine Oil Requirements:
Engine Oil Viscosity
Maximum Angles of Inclination During Operation
Selection of Marine Gear Oil
Engine Coolant
Engine Coolant Specifications
Coolant (Closed Cooling System)
Principal Engine Specifications
Engine Service Standards
Tightening Torques for Standard Bolts and Nuts
Tightening Fasteners
Abbreviations and Symbols
Abbreviations
Symbols
Unit Conversions
Unit Prefixes
Units of Length
Units of Volume
Units of Mass
Units of Force
Units of Torque
Units of Pressure
Units of Power
Units of Temperature
Introduction
The Importance of Periodic Maintenance
Performing Periodic Maintenance
Yanmar Replacement Parts
Required EPA Maintenance - USA Only
EPA Installation Requirements - USA Only
Periodic Maintenance Schedule
Inspection and Maintenance of EPA Emission-Related Parts
Periodic Maintenance Procedures
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EPA Requirements
Conditions to Ensure Compliance with EPA Emission Standards
Inspection and Maintenance
Safety Precautions
Introduction
Principal Engine Specifications
Adjustment Specifications
Cylinder Head Specifications
Cylinder Head and Valves
Camshaft and Timing Gear Train Specifications
Camshaft
Intermediate Gear and Bushing
Timing Gear Backlash
Crankshaft and Pistons Specifications
Crankshaft
Thrust Bearing
Cylinder Liner
Connecting Rod
Piston Ring
Special Torque Chart
Special Service Tools
Measuring Instruments
Tests and Adjustments
Adjust Valve and Unit Injector Clearances
Adjusting Unit Injectors
Digital Caliper Method:
Special Tool Method:
Repair
Cylinder Head
Cylinder Head Components
General Guidelines
Remove and Install Rocker Covers
Upper Rocker Cover
Lower Rocker Cover
Remove the Cylinder Head
Disassemble the Cylinder Head
Clean the Cylinder Head Components
Inspect the Cylinder Head Components
Inspection of Intake and Exhaust Valves
Replace the Valve Stem Seals
Replace the Valve Seat
Removal
Machine the Valves
Machine the Valve Seat Inserts
Specifications
Procedure
Replace the Valve Guides
Replace the Unit Injector Sleeves
Reassemble the Cylinder Head
Install the Cylinder Head
Pistons and Cylinder Liners
Remove and Disassemble Piston and Connecting Rod
Inspect the Connecting Rods
Replace the Wrist Pin Bushing
Inspect the Pistons and Piston Rings
Assemble the Piston and Connecting Rod
Remove the Cylinder Liners
Measure the Cylinder Liner Height
Install the Cylinder Liners
Install the Piston and Connecting Rod
Flywheel and Flywheel Housing
Flywheel Housing Components - 6SY Engines
Flywheel Housing Components - 8SY Engines
Remove the Flywheel
Flywheel Inspection and Repair
Support Bearing Replacement
Remove the Ring Gear
Replace the Rear Crankshaft Seal
Remove the Flywheel Housing
Install the Flywheel Housing
Install the Flywheel
Timing Gear Train
6SY Components
8SY Components
Check the Camshaft Timing
6SY Engines
8SY Engines
Remove the Front Gear Housing - 8SY
Install the Front Gear Housing - 8SY
Intermediate Gear
Remove
Bearing Replacement - 6SY
Bearing Replacement - 8SY
Intermediate Gear Installation
Camshaft Gear
Remove
Install
Crankshaft Gear
Remove
Install
Remove the Camshaft
Replace the Camshaft Bearings - 6SY
Replace the Camshaft Bearings - 8SY
Install the Camshaft
Cylinder Block and Crankshaft
Remove the Crankshaft
Measure the Oil Clearance
Inspect the Crankshaft
Recondition the Crankshaft
Checking and Grinding
Inspect the Cylinder Block
Reconditioning
Install Crankshaft
Replace the Front Crankshaft Seal
Exhaust Manifold
Replacing Gaskets
Make sure that all connections are tightened to specifications after repair is made to the exhaust system.
Lifting the Engine
6SY Engines
8SY Engines
Attaching Engine to Repair Stand
Safety Precautions
Introduction
Specifications
Special Service Tools
Fuel System Components
Fuel Delivery Components
Fuel Injector Components
Tests and Adjustments
Adjust the Unit Injectors
Measure the Fuel Feed Pump Pressure
Procedure
Results
Test the Fuel Pressure Relief Valve
Procedure
Results
Repair
Remove the Unit Injector
Install the Unit Injector
Replace the Fuel Feed Pump
If the fuel feed pump refuses to prime:
Replace the Fuel Filter and Fuel Filter / Water Separator
Replace the Fuel Filter
Replace the Fuel Filter / Water Separator
Replace Return Fuel Line
6SY Engines
8SY Engines
Bleed the Fuel System
If the engine fails to start after bleeding:
Introduction
Specifications
Special Service Tools
Measuring instruments
Tests and Adjustments
Pressure Testing Cooling System and Filler Cap
Cooling System
Filler Cap
Testing the Thermostat
Repair
Drain, Flush and Fill the Engine with Engine Coolant
Venting the Cooling System - 8SY Engines Only
Coolant Pump Removal
Install Coolant Pump
Remove and Install Pulley
Change the Coolant Pump Seal
Remove and Install Thermostat
6SY Thermostat Removal
Thermostat Removal - 8SY
Thermostat Installation - All Engines
Remove and Install Fresh Water Charge Air Cooler
Remove and Install Seawater Charge Air Cooler - 6SY Engines Only
Remove and Install the Heat Exchanger
6SY Engines
8SY Engines
Seawater Pump
Replace the Impeller
Remove and Disassemble Seawater Pump
Inspect the Seawater Pump
Assemble the Seawater Pump
Check or Replace the Zinc Anodes
Introduction
Specifications
Special Service Tools
Tests and Adjustments
Check the Engine Oil Pressure
Repair
Remove and Install the Oil Cooler
6SY Engines
8SY Engines
Remove and Install Oil Cleaning Components
Replace the Engine Oil Filter - 8SY
Clean the Centrifugal Engine Oil Cleaner
Oil Pump
Removal of Oil Pump
Installation of Oil Pump
Introduction
General Information
Oil Leaks
Foreign Bodies
Air and Exhaust Leaks
Oil Filter
Cleaning the Compressor Wheel
Specifications
Special Service Tools
Component Location
6SY Engines
8SY Engines
Tests and Adjustments
Measuring Charge Pressure
Repair
If the Turbocharger Does Not Operate:
Remove Turbocharger
Inspect the Turbocharger
Cleaning the Compressor
Measure the Radial and Axial Clearance
Radial Clearance
Axial Clearance
Install the Turbocharger
Before You Begin Servicing
Introduction
Starter Motor Specifications
Starter Motor Troubleshooting
Remove and Install Starter Motor
Repair Starter Motor - Bosch JE
Components
Brush Replacement
Equipment Required
Repair
Replace Solenoid
Before You Begin Servicing
Introduction
Specifications
Calculating Alternator Capacity
Alternator and Charging System Troubleshooting
Test and Inspection
Output Test
Brush Length
Rotor
Slip Rings
Resistance
Repair
Replace Alternator Belt
Introduction
Specifications
Specifications
Special Service Tools
Function Description - Engine Management System (EMS S6)
General
Component Location
6SY Engines
8SY Engines
Engine Speed Sensors - T28 and T29
Charge Air Pressure and Temperature Sensor - T26
Charge Air Pressure Sensor
Charge Air Temperature Sensor
Coolant Temperature Sensor - T27
Oil Pressure Sensor - T25
EMS S6 Control Unit E44
Function of EMS S6 Control Unit
EMS S6 Control Unit Connections
EMS S6 Control Unit Pin Assignments
Repair
Replace the EMS S6 Control Unit
6SY Engines
Remove the EMS S6 Wiring
Installing EMS S6 Wiring
Wiring and Cable Duct - 6SY
Introduction
Troubleshooting Chart
Fault Codes
Working Procedure
After Troubleshooting or Repair

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