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Yanmar HA Series & HAL Series Marine / Industrial Diesel Engines Service Repair Manual – PDF Download
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Description
Yanmar HA Series & HAL Series Marine / Industrial Diesel Engines Service Repair Manual
FILE DETAILS:
Yanmar HA Series & HAL Series Marine / Industrial Diesel Engines Service Repair Manual
LANGUAGE:ENGLISH
PAGES:261
DOWNLOADABLE:YES
FILE TYPE:PDF
YANMAR HA SERIES & HAL SERIES MARINE / INDUSTRIAL DIESEL ENGINES SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Yanmar HA Series & HAL Series Marine / Industrial Diesel Engines Service Repair Manual
1. Use only Yanmar parts. Use recomended lubri- cants or their equivalent Parts and lubricants that do not meet Yanmar’s design speciflcations may damage the engine.
2. Use the correct special tools designed for this product.
3. Install new gaskets, O—rings, cotter pins. lock plates, lock wires etc. when reassembling.
4. When torquing bolts or nuts, begin with larger- diamater or inner beit first, and tighten to the specified torque diagonally, unless a particular sequence is specified.
5. Clean parts in cleaning solvent after disassembly. Lubricate any sliding surface before massembly.
6. When installing a new oil seal, make sure that the seal lip is coated with grease (however, coat the front oil sea! with engine oil). After clean. ing the oil seal or related parts, coat the seal lip with grease.
7. After reassembly, check all parts for proper in- stallation and operation.
TABLE OF CONTENTS:
Yanmar HA Series & HAL Series Marine / Industrial Diesel Engines Service Repair Manual
COVER............................................................. 1
CONTENTS.......................................................... 3
Sec.1. GENERAL INFORMATION (GI).................................. 4
1. External View............................................. 5
[1-1.] 4HAL Industrial Engine............................ 5
[1-2.] 6HAL Industrial Engine............................ 6
[1-3.] 6HAL-T Industrial Engine.......................... 7
[1-4.] 6HAE Marine Engine................................ 8
[1-5.] 6HA-HTE Marine Engine............................. 9
2. Specifications............................................ 10
[2-1.] Industrial Engine................................. 10
[2-2.] Marine Engine..................................... 11
3. Performance Curves........................................ 17
[3-1.] 4HAL Industrial Engine............................ 17
[3-2.] 6HAL Industrial Engine............................ 17
[3-3.] 6HAL-T Industrial Engine.......................... 17
[3-4.] 6HAL-HT Industrial Engine......................... 17
[3-5.] 6HAE and 6HAME Marine Engine...................... 18
[3-6.] 6HA-HTE and 6HAM-HTE Marine Engine................ 18
4. Sectional Views........................................... 19
[4-1.] 6HAL-T Industrial Engine.......................... 19
[4-2.] 6HA-HTE Marine Engine............................. 20
5. Accessories............................................... 21
[5-1.] Industrial Engine................................. 21
[5-2.] Marine Engine..................................... 23
6. Model Identification...................................... 27
7. Fuel, Lubricant and Coolant............................... 28
[7-1.] Recommended Fuel.................................. 28
[7-2.] Recommended Lubricating Oil....................... 28
{7-3.] Coolant........................................... 29
8. Service Rules............................................. 29
9. Standard Tightening Specifications........................ 29
10. Special Tools............................................. 30
Sec.2. MAINTENANCE (MI).......................................... 34
1. Maintenance Schedule...................................... 35
[1-1.] Industrial Engine................................. 35
[1-2.] Marine Engine..................................... 36
2. Maintenance Procedure..................................... 37
[2-1.] Fuel System....................................... 37
[2-2.] Lubrication System................................ 39
[2-3.] V-belt............................................ 42
[2-4.] Cooling System (Industrial Engine)................ 42
[2-5.] Sea Water System ( Marine Engine)................. 44
[2-6.] Fresh Water System ( Marine Engine)............... 46
[2-7.] Valve Clarance.................................... 48
[2-8.] Air Cleaner(Industrial Engine).................... 49
[2-9.] Turbocharger...................................... 49
Sec.3. CYLINDER HEAD AND VALVE (CH).............................. 51
1. Service Information ...................................... 52
[1-1.] Description....................................... 52
[1-2.] Tools and Materials............................... 53
[1-3.] Torque Values..................................... 53
[1-4.] Specifications.................................... 53
2. Removal................................................... 54
[2-1.] Industrial Engine................................. 54
[2-2.] Marine Engine..................................... 55
3. Disassembly............................................... 55
[3-1.] Rocker Arm Shaft.................................. 55
[3-2.] Cylinder Head..................................... 55
4. Inspection and Repair..................................... 56
[4-1.] Cylinder Head Cover............................... 56
[4-2.] Rocker Arm and Shaft.............................. 56
[4-3.] Cylinder Head..................................... 57
[4-4.] Valve, Valve Guide and Valve Seat................. 57
[4-5.] Valve Spring .................................... 60
[4-6.] Nozzle Sleeve..................................... 60
5. Assembly ................................................. 62
[5-1.] Cylinder Head..................................... 62
[5-2.] Rocker Arm........................................ 63
6. Installation.............................................. 63
Sec.4. ENGINE PROPER (EP)........................................ 65
1. Service Information....................................... 66
[1-1.] Tools and Materials............................... 66
[1-2.] Torque Values..................................... 66
[1-3.] Specifications.................................... 67
2. Piston and Connecting Rod................................. 68
[2-1.] Description....................................... 68
[2-2.] Removal........................................... 69
[2-3.] Inspection........................................ 70
[2-4.] Installation...................................... 74
3. Cylinder Liner............................................ 76
[3-1.] Description....................................... 76
[3-2.] Inspection........................................ 76
[3-3.] Replacement....................................... 77
4. Gear Train................................................ 78
[4-1.] Description....................................... 78
[4-2.] Removal........................................... 79
[4-3.] Inspection ....................................... 80
[4-4.] Installation...................................... 81
5. Camshaft and Valve Train.................................. 83
[5-1.] Description....................................... 83
[5-2.] Removal........................................... 83
[5-3.] Inspection........................................ 84
[5-4.] Installation...................................... 85
6. Crankshaft................................................ 85
[6-1.] Description....................................... 85
[6-2.] Removal........................................... 86
[6-3.] Inspection ....................................... 87
[6-4.] Installation...................................... 90
7. Cylinder Block............................................ 92
[7-1.] Description....................................... 92
[7-2.] Inspection ....................................... 92
[7-3.] Oil Passage Cleaning.............................. 93
Sec.5. LUBRICATION SYSTEM (LS)................................... 94
1. Service Information....................................... 95
[1-1.] Description....................................... 95
[1-2.] Tools and Materials............................... 97
[1-3.] Specifications.................................... 97
2. Oil Pump.................................................. 98
[2-1.] Removal........................................... 98
[2-2.] Inspection ....................................... 98
[2-3.] Installation...................................... 98
3. Oil Filter................................................ 99
[3-1.] Description....................................... 99
[3-2.] Inspection ....................................... 99
4. Oil Coller................................................ 99
[4-1.] Description....................................... 99
[4-2.] Removal...........................................100
[4-3.] Inspection .......................................100
[4-4.] Installation......................................101
5. Pressure Regulator Valve..................................101
[5-1.] Description.......................................101
[5-2.] Inspection .......................................101
[5-3.] Adjustment........................................101
Sec.6. COOLING SYSTEM (CS).......................................102
1. Service Information.......................................103
[1-1.] Description.......................................103
[1-2.] Tools and Materials...............................105
[1-3.] Specifications....................................105
2. Cooling Water Pump (Industrial Engine)....................106
[2-1.] Removal...........................................106
[2-2.] Mechanical Seal Replacement.......................107
[2-3.] Inspection .......................................107
[2-4.] Installation......................................108
3. Sea Water Pump (Marine Engine)............................108
[3-1.] Removal...........................................109
[3-2.] Disassembly.......................................109
[3-3.] Inspection .......................................109
[3-4.] Assembly..........................................109
[3-5.] Installation......................................110
4. Fresh Water Pump (Marine Engine)..........................110
[4-1.] Removal...........................................111
[4-2.] Mechanical Seal Replacement.......................112
[4-3.] Inspection .......................................112
[4-4.] Installation......................................112
5. Heat Exchanger............................................112
[5-1.] Description.......................................112
[5-2.] Removal...........................................113
[5-3.] Inspection .......................................113
[5-4.] Installation......................................113
6. Pressure Cap and Reserve Tank.............................113
[6-1.] Description.......................................113
[6-2.] Inspection .......................................114
7. Thermostat................................................114
[7-1.] Description.......................................114
[7-2.] Inspection .......................................114
[7-3.] Thermostat Installation...........................114
8. Cap and System Leak Test..................................114
[8-1.] Pressure Cap Test.................................114
[8-2.] Water LeakTest (Fresh Water)......................115
9. Removing Scales (During Disassembly)......................116
10. Anti-Corrosion Agent......................................116
[10-1.] Effects of Yanmar Anti-Corrosion Agent............116
[10-2.] How to use Yanmar Anti-Corrosion Agent............116
11. Antifreeze...............................................116
Sec.7. FUEL SYSTEM (FS)..........................................117
1. Service Information.......................................118
[1-1.] Description.......................................118
[1-2.] Tools and Materials...............................119
[1-3.] Specifications....................................119
2. Injection Nozzle..........................................122
[2-1.] Description.......................................122
[2-2.] Removal...........................................122
[2-3.] Inspection ......................................123
[2-4.] Installation......................................124
3. Injection Pump............................................125
[3-1.] Description.......................................125
[3-2.] Removal...........................................127
[3-3.] Disassembly.......................................128
[3-4.] Inspection ......................................136
[3-5.] Assembly..........................................137
[3-6.] Adjustment........................................143
[3-7.] Installation......................................147
[3-8.] Adjustment........................................148
4. Feed Pump.................................................149
[4-1.] Description.......................................149
[4-2.] Disassembly.......................................150
[4-3.] Assembly..........................................150
[4-4.] Inspection ......................................151
[4-5.] Test..............................................151
5. Governor..................................................152
[5-1.] Description.......................................152
[5-2.] Disassembly.......................................154
[5-3.] Assembly..........................................157
6. Automatic Timer (Marine Engine Only)......................158
[6-1.] Description.......................................158
Sec.8. INTAKE EXHAUST SYSTEM (IE)................................160
1. Service Information.......................................161
[1-1.] Tools and Materials...............................161
[1-2.] Specifications....................................161
2. Intake System ............................................161
[2-1.] Removal...........................................161
[2-2.] Inspection ......................................162
[2-3.] Installation......................................162
3. Exhaust System........................................162
[3-1.] Removal...........................................162
[3-2.] Inspection ......................................163
[3-3.] Installation......................................163
4. Turbocharger (6HAL-T, 6HAL-HT and 6HA(M)-HTE).............163
[4-1.] Description.......................................163
[4-2.] Removal...........................................163
[4-3.] Disassembly.......................................164
[4-4.] Cleaning..........................................165
[4-5.] Inspection ......................................166
[4-6.] Assembly..........................................167
[4-7.] Storage...........................................169
[4-8.] Installation......................................169
Sec.9. ELECTRICAL SYSTEM (ES)....................................171
1. Battery and Charging System...............................172
[1-1.] Service Information...............................172
[1-2.] Battery...........................................176
[1-3.] Alternator........................................178
[1-4.] Regulator (Industrial Engine Only)................185
2. Starting System...........................................186
[2-1.] Servica Information...............................186
[2-2.] Removal...........................................190
[2-3.] Disassembly.......................................190
[2-4.] Inspection ......................................191
[2-5.] Assembly..........................................195
[2-6.] Installation......................................195
[2-7.] Adjustment........................................195
3. Instruments...............................................196
[3-1.] Tachometer........................................196
[3-2.] Hour Meter........................................197
[3-3.] Cooling Water Temperature Gauge...................197
[3-4.] Lub. Oil Pressure Gauge...........................198
4. Warning System (Marine Engine Only).......................199
[4-1.] Service Information...............................199
[4-2.] Inspection ......................................200
Sec.10. ENGINE EMERGENCY STOP SYSTEM (EE).........................204
1. Service Information.......................................205
[1-1.] Description.......................................205
[1-2.] Tools and Materials...............................205
[1-3.] Specifications....................................205
2. Electrical Stop System....................................205
[2-1.] Description.......................................205
[2-2.] Inspection ......................................206
3. Mechanical System.........................................207
[3-1.] Description.......................................207
[3-2.] Temperature Detecting Valve Inspection............208
[3-3.] Controller Operating Pressure Inspection..........209
Sec.11. ENGINE INSTALLATION (EI)..................................210
1. Industrial Engine.........................................211
[1-1.] Output Correction.................................211
[1-2.] Clutch Capacity...................................212
[1-3.] Side Load.........................................212
[1-4.] Engine Room.......................................213
[1-5.] Dimensional Drawing...............................214
[1-6.] Mounting Foundation of the Stationary Engine......217
[1-7.] Carrying in the Engine............................217
[1-8.] Centering.........................................217
[1-9.] Anchor Bolts and Support Washers..................219
[1-10.] Concreting........................................219
[1-11.] Final Centering...................................219
[1-12.] Fuel System.......................................221
[1-13.] Exhaust System....................................222
[1-14.] Electrical System.................................223
2. Marine Engine.............................................224
[2-1.] Engine Room.......................................224
[2-2.] Engine Bed........................................224
[2-3.] Dimensional Drawing...............................225
[2-4.] Carring the Engine into the Engine Room...........226
[2-5.] Engine Installation...............................228
[2-6.] Engine Centering..................................228
[2-7.] Final Centering...................................229
[2-8.] Piping Diagram....................................230
[2-9.] Fuel System.......................................232
[2-10.] Sea Water Cooling System..........................232
[2-11.] Fresh Water Cooling System........................232
[2-12.] Exhaust System....................................233
[2-13.] Crankcase Breather................................234
[2-14.] Bilge Rump........................................235
[2-15.] Remote Control....................................235
[2-16.] Electrical System.................................236
Sec.12. TROUBLESHOOTING (TS)......................................237
Troubleshooting...............................................238
Sec.13. MARINE GEAR (MG)..........................................241
1. Service Information.......................................242
[1-1.] Description.......................................242
[1-2.] Sectional View....................................245
[1-3.] Tools and Materials...............................247
[1-4.] Specifications....................................247
[1-5.] General Instructions..............................248
2. Oil Pump/Selector Valve..................................249
[2-1.] Removal...........................................249
[2-2.] Disassembly of Gear Pump..........................249
[2-3.] Disassembly of Selector Valve.....................249
[2-4.] Inspection ......................................251
[2-5.] Assembly..........................................251
[2-6.] Installation......................................251
3. Input Shaft/Gear Shaft....................................251
[3-1.] Removal...........................................251
[3-2.] Disassembly of Input Shaft........................252
[3-3.] Disassembly of Gear Shaft.........................254
[3-4.] Inspection ......................................254
[3-5.] Assembly..........................................254
[3-6.] Installation......................................255
4. Output Shaft..............................................255
[4-1.] Removal...........................................255
[4-2.] Inspection ......................................257
[4-3.] Installation......................................257
5. Input Shaft Flange.........................................257
[5-1.] Removal...........................................257
[5-2.] Installation......................................257
6. Oil Strainer Cleaning.....................................258
7. Shim Adjustment...........................................258
[7-1.] Adjustment of Input Shaft and Gear Shaft Shims....258
[7-2.] Adjustment of Output Shaft Shim...................259
8. Troubleshooting...........................................260
BACK COVER........................................................261
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