Yanmar 6CX530 Service Workshop Manual

Workshop Service and Repair Manual for the Yanmar 6CX530 marine engine, an absolute must-have for any Yanmar owner. This full workshop manual covers every component, service and repair procedure in full Yanmar factory specification with clear step by step photographs and technical drawings for the 6CX530 with torque setting values throughout each chapter, this is the most comprehensive service manual available as used by boatyards and independent marine engineers the world over.

Below is an exhaustive list of the items and procedures covered within this manual:

General service information
Safety Precautions
6CX530 Exterior Views
Right Side (Viewed from Flywheel)
Left Side (Viewed from Flywheel
Diesel Fuel
Diesel Fuel Specifications
Filling the Fuel Tank
Bleeding the Fuel System
Engine Oil
Engine Oil Specifications
Engine Oil Viscosity
Engine Oil System
Checking the Engine Oil
Adding Engine Oil
Marine Gear
Marine Gear Oil Specifications
Checking Marine Gear Oil
Adding Marine Gear Oil
Engine Coolant
Handling Coolant
Checking and Adding Coolant
Checking the Engine Oil and Engine Coolant
Engine Outline Drawings
6CX530 with KMH70A Marine Gear (Barry Control Mount)
6CX530 (Bobtail)
6CX530 (Application)
6CX530 Engine Only

periodic maintenance:
Safety Precautions
Introduction
The Importance of Periodic Maintenance
Performing Periodic Maintenance
The Importance of Daily Checks
Keep a Log of Engine Hours and Daily Checks
Yanmar Replacement Parts
Tools Required
Tightening Fasteners
EPA Maintenance Requirements
EPA Requirements for USA and Other Applicable Countries
EPA Requirements
Conditions to Ensure Compliance with
EPA Emission Standards
Inspection and Maintenance
Periodic Maintenance Schedule
Inspection and Maintenance of EPA Emission-Related
Parts
Periodic Maintenance Procedures
Daily Checks
After Initial 50 Hours of Operation
Every 50 Hours of Operation
Every 250 Hours of Operation
Every 500 Hours of Operation
Every 1000 Hours of Operation
Long-Term Storage (Cooling System)

Engine:
Safety Precautions
Introduction
Disassembling the Engine and Components
Precautions Before Engine Disassembly
Special Tools
Removing the Engine from the Vessel
Draining the Coolant
Draining the Engine Oil
Removing the Covers
Removing the Electrical Wiring
Removing the Relay and Fuse Boxes
Removing the Fuel Filter and Fuel Hoses
Removing the Belt Cover
Removing the Coolant Hoses
Removing the Air Silencer
Removing the Charge Air Cooler
Removing the Turbocharger
Removing the Starter Motor
Removing the Alternator
Removing the Coolant Tank, Oil Cooler and Pump
Removing the Seawater Pump
Removing the Oil Filter and Oil Cooler
Removing the Fuel Injection Lines
Removing the Fuel Injectors
Removing the Fuel Supply Pump and Common Rail
Removing the Rocker Arm Shaft Assembly
Removing the Cylinder Head
Removing the Marine Gear
Removing the Crankshaft Damper
Removing the Flywheel and Flywheel Housing
Turning the Engine Block Over
Removing the Oil Pan and Oil Pump
Removing the Connecting Rod End Caps
Removing the Main Bearing Bolts
Disassembling the Crankshaft and Piston Assemblies
Inspecting the Cylinder Block and Components:
Dye Penetrant Inspection Procedure
Measuring the Cylinder Bores
Cylinder Head Components and Functions
Inspecting the Cylinder Head
Inspecting the Pistons and Piston Pins
Inspecting the Connecting Rods
Inspecting the Crankshaft
Inspecting the Camshaft and Tappets
Inspecting the Tappets
Inspecting the Push Rods
Inspecting the Timing Gear
Inspecting the Idler Gear
Indexing the Gear Timing Marks
Inspecting the Flywheel and Housing
Replacing the Ring Gear
Positioning Top Dead Center
Inspecting the Intake/ Exhaust System
Assembling the Engine and Components:
Precautions Before Assembling the Engine
Installing the Piston Cooling Nozzles
Installing the Crankshaft
Installing the Camshaft Bearings
Installing the Drive Shaft Housing
Installing the Camshaft
Installing the Oil Pump
Installing the Oil Pan
Installing the Flywheel Housing Oil Seal
Installing the Flywheel Housing
Installing the Engine Mounts
Installing the Tappets
Installing the Covers
Installing the Idler Gear
Installing the Seawater Pump
Installing the Piston Assemblies
Installing the Coolant Passage Covers
Installing the Cylinder Block Side Covers
Installing the Fuel Supply Pump
Installing the Flywheel
Installing the Cylinder Head Assembly
Installing the Push Rod and Valve Rocker Arm Shaft Assembly
Installing the Rocker Arm Housings and Covers with Packing
Installing the Engine Lifters
Installing the Engine Oil Cooler
Installing the Oil Seal to the Drive Shaft Housing Cover Using the Correct Insert Tool
Installing the Drive Shaft Housing Cover
Installing the Belt-Pulley and Damper
Installing the Breather to Drive Shaft Housing Cover Side
Installing the Bearing Housing and Pulley
Installing the Alternator and Belt
Installing the Oil Filter Head
Installing the Engine Oil Filters
Installing the Breather Hose Assembly
Installing the Engine Oil Pipes
Installing the Oil Cooler to the Cylinder Block with
Supports for Exhaust Manifold and Heat Exchanger
Installing the Seawater Pipes and Hoses
Installing the Coolant Pump
Installing the Exhaust Manifold
Installing the Heat Exchanger
Installing the Intake Manifold
Installing the Charge Air Cooler
Installing the Marine Gear
Installing the Fuel Injector
Tightening the Common Rail Bolts
Installing High-Pressure Fuel Pipe Lines
Tightening the High-Pressure Fuel Lines
Tightening the High-Pressure Fuel Pipes from Supply
Pump to Common Rail
Installing the Fuel Return Pipes
Low-Pressure Fuel Pipe Line Tightening Torque around Common Rail System (CRS) Parts
Installing the Seawater Bends and Hoses
Installing the Coolant Bend
Installing the Rocker Arm Cover
Installing the Engine Turbocharger (HOLSET HX50)
Installing the Engine Air Ducts
Installing the Oil Mist Pipe and Hose
Installing the Turbocharger Cover (Freshwater Cooled)
Installing the Air Duct Cover
Installing the Mixing Elbow (Not Supplied by Yanmar)
Installing the Oil Lines for the Fuel High-Pressure Pump
Installing the Fuel Filter and Fuel/ Water Separator
(Not Supplied by Yanmar)
Installing the Electric Relays and Fuses
Installing the Engine Control Unit (ECU)
Installing the Engine Driver Unit (EDU) for Fuel Injector
and Pressure Valve
Installing the Alternator Fuse
Installing the Sensors and Wire Harnesses
Installing the Relay Cover
Installing the ECU Cover
Installing the Air Duct Cover

Fuel system:
Safety Precautions
Introduction
Specifications
Fuel High-Pressure Supply Pump/ Fuel Feed Pump/
Fuel Priming Pump
Fuel High-Pressure Supply Pump Components
Removing the Fuel High-Pressure Supply Pump
Removing Fuel Common Rail
Installing the Fuel High-Pressure Supply Pump
Installing Wire Harnesses from Two Pressure Sensors
and Pressure Relief Valve
Installing Fuel Common Rail
Troubleshooting the Fuel Injection System
Fuel Injector Components and Functions
Fuel Injector Specifications
Fuel Feed Pump Components and Functions
Fuel Feed Pump Components
Fuel/ Water Separator Components and Functions
Inspecting and Draining Water
Fuel Filter and Functions
Inspecting the Fuel Filter
Engine Control System Diagram
Sensors and Actuators
Outline of Control Flow in Normal Mode
Outline of Control Flow in Start Mode

Cooling system:
Safety Precautions
Introduction
Cooling System Components and Functions
Cooling System Components
Seawater Pump Components and Functions
Disassembling the Seawater Pump
Inspecting the Seawater Pump
Assembling the Seawater Pump
Coolant Pump Components and Functions
Cooling System Components
Disassembling the Coolant Pump
Inspecting the Coolant Pump
Heat Exchanger Components and Functions
Heat Exchanger Components
Inspecting the Heat Exchanger
Pressure Cap Operation
Inspecting the Pressure Cap
Coolant Recovery Tank Components and Functions
Installing the Coolant Recovery Tank
Coolant Recovery Tank Precautions
Thermostat Components and Functions
Inspecting the Thermostat
Testing the Thermostat
Seacock Components and Functions (Optional)
Seacock Precautions
Inspecting the Seacock
Bilge Pump and Strainer Components and Functions (Optional)
Bilge Pump Characteristics
Bilge Pump Insulation
Bilge Pump Durability
Bilge Pump Vibration Proof
Bilge Pump Precautions
Installing the Bilge Pump
Troubleshooting the Bilge Pump

Lubrication:
Safety Precautions
Introduction
Lubrication Components and Functions
Oil Pump Components and Functions
Oil Pump Specifications
Oil Pump Components
Removing the Oil Pump
Inspecting the Oil Pump
Installing the Oil Pump
Oil Pressure Control Valve Components and Functions
Replacing the Oil Pressure Control Valve
Oil Filter Components and Functions
Oil Pressure Relief Valve for Bypass Circuit
Replacing the Oil Filter
Oil Cooler Functions
Inspecting the Oil Cooler

Turbocharger:
Safety Precautions
Introduction
Turbocharger Components and Functions
Turbine
Compressor
Bearings
Seal Structure of the Compressor Housing
Disassembling the Turbocharger
Disassembly Procedure
Assembling the Turbocharger
Reassembly Procedure
Maintenance Standard Chart
Tightening Torque Chart
Handling the Turbocharger
Precautions for Installing the Turbocharger to the Engine
Troubleshooting the Turbocharger
Black Smoke
White Smoke
Excessive Oil Consumption
Reduced Engine Power
Poor Follow-Up of the Turbocharger
Unusual Sound or Vibration

Starter:
Safety Precautions
Introduction
Starter Components and Functions
Starter Specifications
Starter Characteristics
Starter Components
Starter Operation
Starter Wiring Diagram

Electrical:
Safety Precautions
Introduction
Battery Components and Functions
Battery Capacity and Battery Cables
Inspecting the Battery
Charging the Battery
Precautions for Battery Storage
DC/DC Converter for 24V Optional Battery
Wiring Diagram
ECU Connector Pin Configuration
Sensor Locations
Sensors for Oil Pressure and Boost Pressure
Sensor for Cooling Water Temperature
Sensor for Intake Air Temperature and Pressure
Sensors for Exhaust Temperature
Sensor for Coolant Level
Speed Sensors (Cam Gear and Rotor)
Air Heater Components and Functions
Air Heater Operation
Fuse, Relay and Harness Components
Fuse Chart (12V Standard/ 24V Optional)
Digital Display
Rocker Switch Panel
Control Head (Shift and Throttle)

Troubleshooting:
Safety Precautions
Introduction
Preparation Before Troubleshooting
Digital Display Indications
Troubleshooting Procedure
6CX530 Engine Check Sheet
Troubleshooting By Symptom
Troubleshooting By OTC Fault Codes

Service Standards:
Engine
Cylinder Head
Camshaft and Gear Train
Cylinder Block and Crankshaft
Piston Ring
Connecting Rod
Tightening Torque for Bolts and Nuts
Main Bolt and Nut
Standard Bolts and Nuts (Without Oil)

Diagnostic trouble codes (DTSC)
Method & procedure of failure diagnosis