Yanmar 6CXS30 Marine Diesel Engine Repair Service Manual

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This Workshop Service Repair manual PDF download for the 6CXS30 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 6CX530 :
Yanmar Inboard Engine 530hp/390kW - EPB5668


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part Number : 086CX-G00100
Total Pages : 497


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 !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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Cover
TABLE OFCONTENTS
INTRODUCTION
SAFETY
GENERAL SERVICEINFORMATION
SAFETY PRECAUTIONS
6CX530 EXTERIOR VIEWS
DIESEL FUEL
ENGINE OIL
MARINE GEAR
ENGINE COOLANT
CHECKING THE ENGINE OILAND ENGINE COOLANT
ENGINE OUTLINE DRAWINGS
EXHAUST GAS EMISSION REGULATIONS
LOCATION OF NAMEPLATES
6CX530 ENGINE SPECIFICATIONS
ABBREVIATIONS AND SYMBOLS
UNIT CONVERSIONS
PERIODICMAINTENANCE
SAFETY PRECAUTIONS
INTRODUCTION
EPA MAINTENANCEREQUIREMENTS
PERIODIC MAINTENANCESCHEDULE
PERIODIC MAINTENANCEPROCEDURES
LONG-TERM STORAGE(COOLING SYSTEM)
ENGINE
SAFETY PRECAUTIONS
INTRODUCTION
DISASSEMBLING THE ENGINEAND COMPONENTS
INSPECTING THE CYLINDERBLOCK AND COMPONENTS
ASSEMBLING THE ENGINE ANDCOMPONENTS
FUEL SYSTEM
SAFETY PRECAUTIONS
INTRODUCTION
SPECIFICATIONS
FUEL HIGH-PRESSURE SUPPLYPUMP / FUEL FEED PUMP /FUEL PRIMING PUMP
FUEL INJECTOR COMPONENTSAND FUNCTIONS
FUEL FEED PUMPCOMPONENTS ANDFUNCTIONS
FUEL / WATER SEPARATORCOMPONENTS ANDFUNCTIONS
FUEL FILTER AND FUNCTIONS
ENGINE CONTROL SYSTEMDIAGRAM
COOLING SYSTEM
SAFETY PRECAUTIONS
INTRODUCTION
COOLING SYSTEMCOMPONENTS ANDFUNCTIONS
SEAWATER PUMPCOMPONENTS ANDFUNCTIONS
COOLANT PUMP COMPONENTSAND FUNCTIONS
HEAT EXCHANGERCOMPONENTS ANDFUNCTIONS
COOLANT RECOVERY TANKCOMPONENTS ANDFUNCTIONS
THERMOSTAT COMPONENTSAND FUNCTIONS
SEACOCK COMPONENTS ANDFUNCTIONS (OPTIONAL)
12/056CX530 Service Manual 7-21© 2009 Yanmar Marine InternationalBILGE PUMP AND STRAINER COMPONENTS AND FUNCTIONS(OPTIONAL)
BILGE PUMP AND STRAINER COMPONENTS AND FUNCTIONS(OPTIONAL)
LUBRICATION
SAFETY PRECAUTIONS
INTRODUCTION
LUBRICATION COMPONENTSAND FUNCTIONS
OIL PUMP COMPONENTS ANDFUNCTIONS
OIL FILTER COMPONENTS ANDFUNCTIONS
OIL COOLER FUNCTIONS
TURBOCHARGER
SAFETY PRECAUTIONS
INTRODUCTION
TURBOCHARGER COMPONENTS AND FUNCTIONS
DISASSEMBLING THE TURBOCHARGER
ASSEMBLING THE TURBOCHARGER
MAINTENANCE STANDARD CHART
TIGHTENING TORQUE CHART
HANDLING THETURBOCHARGER
TROUBLESHOOTING THETURBOCHARGER
STARTER
SAFETY PRECAUTIONS
INTRODUCTION
STARTER COMPONENTS ANDFUNCTIONS
ALTERNATOR
SAFETY PRECAUTIONS
INTRODUCTION
ALTERNATOR COMPONENTSAND FUNCTIONS
ELECTRICAL
SAFETY PRECAUTIONS
INTRODUCTION
BATTERY COMPONENTS ANDFUNCTIONS
WIRING DIAGRAM
WARNING DEVICES
AIR HEATER COMPONENTSAND FUNCTIONS
FUSE, RELAY AND HARNESSCOMPONENTS
REMOTE CONTROL ELECTRONIC CONTROL SYSTEM (ECS)
TROUBLESHOOTING
SAFETY PRECAUTIONS
INTRODUCTION
PREPARATION BEFORETROUBLESHOOTING
TROUBLESHOOTING PROCEDURE
TROUBLESHOOTING BY SYMPTOM
TROUBLESHOOTING BY DTC FAULT CODES
1. DTCS (DIAGNOSTIC TROUBLE CODES) GENERALDESCRIPTION
1.1 DTC Code List
1.2 Description Items
1.3 Analog Input
1.3.1 Rail Pressure Sensor 1
1.3.2 Rail Pressure Sensor 2
1.3.3 Boost Pressure Sensor
1.3.4 Coolant Temperature Sensor
1.3.5 Intake Air Temperature Sensor
1.3.6 Inlet Fuel Temperature Sensor
1.3.7 Outlet Fuel Temperature Sensor
1.3.8 Engine Oil Pressure Sensor
1.3.9 Exhaust Temperature Sensor
1.3.10 Main Throttle Position Sensor
1.3.11 Sub-Throttle Position Sensor
1.3.12 CAN Throttle
1.3.13 ECU Temperature Sensor
1.3.14 Sensor 5V - 1
1.3.15 Sensor 5V - 2
1.4 Pulse input
1.4.1 Cam Sensor 1
1.4.2 Crank Sensor 1
1.4.3 Cam Sensor 2
1.4.4 Crank Sensor 2
1.4.5 Cam Sensor 1 & Crank Sensor 1
1.4.6 Cam Sensor 2 & Crank Sensor 2
1.5 Actuator Drive
1.5.1 Pressure Control Valve 1 (PCV1)
1.5.2 Pressure Control Valve 2 (PCV2)
1.5.3 Injector Circuit (No. 1 to No. 6)
1.5.4 Injector Communication Power
1.5.5 Pressure Relief Valve (PRV)
1.5.6 PCV Relay
1.5.7 Pressure Relief Valve (PRV) Relay
1.5.8 Engine Driver Unit (EDU) Relay
1.5.9 Intake Air Heater Relay
1.5.10 Main Relay
1.6 Engine
1.6.1 Supply Pump Pressure Too High
1.6.2 Fuel Pumping Timing Advanced Too Much
1.6.3 Supply Pump Pressure Too Low
1.6.4 Supply Pump Feed Back Value Failure
1.6.5 Rail Pressure Too High
1.6.6 Rail Pressure Too High (Over Limit)
1.6.7 Coolant Temperature Too High
1.6.8 Boost Pressure Too High
1.6.9 Inlet Fuel Temperature Too High
1.6.10 Outlet Fuel Temperature Too High
1.6.11 Engine Oil Pressure Too Low
1.6.12 Battery Voltage Too High
1.6.13 Battery Voltage Too Low
1.6.14 Engine Over Speed
1.7 ECU
1.7.1 ECU Temperature Too High
1.7.2 ECU EEPROM (Initialization)
1.7.3 ECU EEPROM (Single Domain)
1.7.4 ECU EEPROM (Triple Domain)
1.7.5 ECU ROM (INDMAP)
1.7.6 ECU ROM (MAP Domain)
1.7.7 ECU ROM (APL Domain)
1.7.8 Injector QR Correction Value
2. METHOD AND PROCEDURE OF FAILURE DIAGNOSIS
2.1 Description Items
2.2 ECU Pin Layout Drawing
2.3 Using a Breakout Box
2.4 Checking Trouble Code (P Code) with the Yanmar Diagnostic Tool (YDT)
2.5 Analog Input
2.5.1 Pressure Sensor
2.5.2 Temperature Sensor
2.5.3 Analog Throttle Sensor
2.5.4 CAN Throttle
2.5.5 Sensor Power Supply
2.6 Pulse Input
2.6.1 Crank Sensor
2.6.2 Cam Sensor
2.7 Actuator Drive
2.7.1 Pressure Control Valve
2.7.2 Injector
2.7.3 Pressure Relief Valve
2.7.4 Relay
2.7.5 Main Relay
SERVICESTANDARDS
SERVICE STANDARDS
TIGHTENING TORQUE FOR BOLTS AND NUTS

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