Yanmar 4BY3-150 to 6BY3-260Z Marine Engine Operation Manual

Description

• Model List:
  • 4BY3-150, 4BY3-150Z, 4BY3-180, 4BY3-180Z, 6BY3-220, 6BY3-220Z, 6BY3-260, 6BY3-260Z

• 1. Table of Contents
• 2. Introduction
• 2.1. Record of Ownership
• 2.2. Safety Precautions
• 2.2.1. General Information
• 2.2.2. Before You Operate
• 2.2.3. During Operation and Maintenance
• 2.3. Safety Decals
• 3. Product Overview
• 3.1. YANMAR BY3-Series Features and Applications
• 3.1.1. New Engine Break In
• 3.2. Component Identification
• 3.2.1. Left Side (as Viewed from Flywheel) – 4BY3
• 3.2.2. Right Side (as Viewed from Flywheel) – 4BY3
• 3.2.3. Top View – 4BY3
• 3.2.4. Left Side – 6BY3
• 3.2.5. Right Side – 6BY3
• 3.2.6. Top View – 6BY3
• 3.3. Location of Nameplates
• 3.4. Function of Major Components
• 3.5. Fuses and Relays
• 3.6. Engine Cover
• 4. Before You Operate
• 4.1. Introduction
• 4.2. Safety Precautions
• 4.3. Diesel Fuel
• 4.3.1. Diesel Fuel Specifications
• 4.3.1.1. Biodiesel fuels
• 4.3.1.2. Additional technical fuel requirements
• 4.3.1.3. Handling of diesel fuel
• 4.3.1.4. Fuel tank (optional)
• 4.3.1.5. Diesel Fuel Lines
• 4.3.2. Filling the Fuel Tank
• 4.3.2.1. Before filling fuel tank for the first time
• 4.3.2.2. To fill the fuel tank
• 4.3.3. Bleeding the Fuel System
• 4.4. Engine Oil
• 4.4.1. Engine Oil Specifications
• 4.4.1.1. Service categories
• 4.4.1.2. Definitions
• 4.4.2. Checking Engine Oil
• 4.4.3. Adding Engine Oil
• 4.5. Marine Gear or Stern Drive Oil
• 4.5.1. Marine Gear Oil Specifications
• 4.5.1.1. KMH41A, KMH51A, KMH50V
• 4.5.2. Stern Drive Oil Specifications
• 4.5.2.1. Mercruiser Bravo
• 4.6. Power Steering Fluid Specifications
• 4.6.1. Power steering oil (stern drive only)
• 4.6.2. Power trim oil
• 4.6.3. Checking Power Steering Fluid Level
• 4.7. Engine Coolant
• 4.7.1. Acceptable Engine Coolant
• 5. Engine Operation
• 5.1. Introduction
• 5.2. Safety Precautions
• 5.3. Starting the Engine
• 5.3.1. Starting at Low Temperatures
• 5.4. Shutting Down the Engine
• 5.4.1. Emergency Shut Down
• 5.5. Checking the Engine After Operation
• 6. Periodic Maintenance
• 6.1. Introduction
• 6.2. Safety Precautions
• 6.3. Precautions
• 6.3.1. The Importance of Periodic Maintenance
• 6.3.2. Performing Periodic Maintenance
• 6.3.3. The Importance of Daily Checks
• 6.3.4. Keep a Log of Engine Hours and Daily Checks
• 6.3.5. YANMAR Replacement Parts
• 6.3.6. Tools Required
• 6.3.7. Ask Your Authorized YANMAR Marine Dealer or Distributor For Help
• 6.3.8. Tightening Fasteners
• 6.4. EPA Maintenance Requirements
• 6.4.1. EPA Requirements for USA and Other Applicable Countries
• 6.4.2. EPA Requirements
• 6.4.3. Installation of Exhaust Sampling Port
• 6.5. Periodic Maintenance Schedule
• 6.5.1. Inspection and Maintenance of EPA Emission-Related Parts
• 6.6. Periodic Maintenance Procedures
• 6.6.1. Daily Checks
• 6.6.2. Visual Checks
• 6.6.3. Checking Diesel Fuel, Engine Oil and Engine Coolant Levels
• 6.6.4. Checking the Battery Electrolyte Level
• 6.6.5. Checking the Alarm Indicators
• 6.6.6. Preparing Fuel, Oil and Coolant in Reserve
• 6.6.7. Checking Power Steering Fluid
• 6.6.8. Draining the Fuel/Water Separator
• 6.6.9. After Initial 50 Hours of Operation
• 6.6.9.1. Changing the engine oil and replacing the engine oil filter
• 6.6.9.2. Checking shift cable adjustment
• 6.6.9.3. Adjusting propeller shaft alignment (if equipped with marine gear)
• 6.6.10. Every 50 Hours of Operation
• 6.6.10.1. Checking the seawater filter (if equipped) and inlet
• 6.6.10.2. Checking the air intake system
• 6.6.10.3. Checking the battery electrolyte level (serviceable batteries only)
• 6.6.11. Every 250 Hours of Operation
• 6.6.11.1. Draining the fuel tank
• 6.6.11.2. Changing the engine oil and replacing engine oil filter element
• 6.6.11.3. Checking or replacing the seawater pump and alternator belts
• 6.6.11.4. Replacing the zinc anodes
• 6.6.11.5. Checking or replacing the seawater pump impeller
• 6.6.11.6. Replacing the turbocharger heat shield
• 6.6.11.7. Checking exhaust/water mixing elbow
• 6.6.11.8. Replacing air filter element
• 6.6.11.9. Checking or replacing alternator belt
• 6.6.11.10. Changing power steering fluid
• 6.6.11.11. Checking shift cable adjustment
• 6.6.11.12. Adjusting the propeller shaft alignment
• 6.6.11.13. Checking hydraulic oil cooler
• 6.6.11.14. Checking or replacing rubber hoses
• 6.6.11.15. Checking or replacing flexible engine mounts
• 6.6.12. Every 500 Hours of Operation
• 6.6.12.1. Checking the fuel pump and fuel lines
• 6.6.12.2. Draining and refilling closed cooling system (engine coolant)
• 6.6.13. Every 1000 Hours of Operation
• 6.6.13.1. Checking flexible engine mounts
• 6.6.14. Every 2000 Hours of Operation
• 6.6.14.1. Replacing seawater pump impeller
• 6.6.14.2. Replacing alternator belt
• 7. Troubleshooting
• 7.1. Safety Precautions
• 7.2. Troubleshooting After Starting
• 7.3. Troubleshooting Information
• 7.4. Troubleshooting Chart
• 7.4.1. Starting Trouble
• 7.4.2. Vibration – Drive Disengaged
• 7.4.3. Vibration – Drive Engaged
• 7.4.4. Engine Knocks
• 7.4.5. Low Power Output
• 7.4.6. Engine Overheat
• 7.4.7. Engine Runs Cold
• 7.4.8. Coolant Loss
• 7.5. Diagnostic Trouble Codes
• 8. Long-Term Storage
• 8.1. Prepare Engine for Long-Term Storage
• 8.1.1. Draining the Seawater Cooling System
• 9. Specifications
• 9.1. Engine Specifications
• 10. EPA Warranty USA Only
• 10.1. YANMAR Co., Ltd. Limited Emission Control System Warranty – USA Only
• 10.1.1. Your Warranty Rights and Obligations
• 10.1.2. Warranty Period
• 10.1.3. Warranty Coverage
• 10.1.4. Exclusions
• 10.1.5. Owners Responsibility
• 10.1.6. Customer Assistance