Yanmar BY series Bedienungsanleitung

BY series

4BY

6BY

SERVICE MANUAL

BY Service Manual

series

SERVICE MANUAL

4BY

6BY

P/N:0BBY0-G00100

MARINE

ENGINES

BY SERVICE MANUAL

ii BY Service Manual

This Service Manual has been developed for the exclusive use of service and repair professionals such as

Yanmar authorized Distributors and Yanmar authorized Dealers. It is written with these professionals in mind

and may not contain the necessary detail or safety statements that may be required for a non-professional to

perform the service or repair properly and / or safely. Please contact an authorized Yanmar repair or service

professional before working on your Yanmar product.

Disclaimers:

All information, illustrations and specifications in this manual are based on the latest information available at

the time of publishing. The illustrations used in this manual are intended as representative reference views

only. Moreover, because of our continuous product improvement policy, we may modify information,

illustrations, and / or specifications to explain and / or exemplify a product, service, or maintenance

improvement. We reserve the right to make any change at any time.

Yanmar and are registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or

other countries.

No part of this publication may be reproduced or used in any form by any means - graphic, electronic, or

mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without

the written permission of Yanmar Marine International.

0406

4BY / 6BY Service Manual iii

4BY / 6BY Service Manual

TABLE OF

CONTENTS

Page

Introduction ......................................................................................... 1-1

Safety.................................................................................................... 2-1

General Service Information .............................................................. 3-1

Periodic Maintenance ......................................................................... 4-1

Engine .................................................................................................. 5-1

Fuel System ......................................................................................... 6-1

Cooling System ................................................................................... 7-1

Lubrication........................................................................................... 8-1

Turbocharger....................................................................................... 9-1

Starter Motor...................................................................................... 10-1

Alternator ........................................................................................... 11-1

Electrical and ECU ............................................................................ 12-1

Troubleshooting................................................................................ 13-1

TABLE OF CONTENTS

iv 4BY / 6BY Service Manual

This Page Intentionally Left Blank

BY Service Manual 1-1

BY Service Manual Section 1

INTRODUCTION

This manual gives specific instructions for the proper repair of Yanmar BY series marine engines.

Please follow the procedures carefully to ensure quality service.

Yanmar recommends that you read this Service Manual completely before starting with repairs, as some of

the procedures described are rather complex.

Along with standard tools, Yanmar recommends the use of special tools necessary to perform repairs

correctly.

Yanmar products are continuously undergoing improvement. This Service Manual has been checked

carefully in order to avoid errors. However Yanmar is not liable for any misrepresentations, errors of

description or omissions. Contact an authorized Yanmar marine dealer or distributor for any questions you

have regarding this Service Manual.

INTRODUCTION

1-2 BY Service Manual

This Page Intentionally Left Blank

BY Service Manual 2-1

BY Service Manual Section 2

SAFETY

Yanmar is concerned for your safety and the

condition of your marine engine. Safety statements

are one of the primary ways to call your attention to

the potential hazards associated with Yanmar

marine engines. Follow the precautions listed

throughout the manual before operation, during

operation and during periodic maintenance

procedures for your safety, the safety of others and

to protect the performance of your marine engine.

Keep the labels from becoming dirty or torn and

replace them if they are lost or damaged. Also, if

you need to replace a part that has a label attached

to it, make sure you order the new part and label at

the same time.

This safety alert symbol appears

with most safety statements. It

means attention, become alert,

your safety is involved! Please read

and abide by the message that

follows the safety alert symbol.

ADANGER

Danger (the word “DANGER” is in white

letters with a red rectangle behind

it) - indicates an imminently hazardous

situation which, if not avoided, will

result in death or serious injury. Danger

is limited to the most extreme

situations.

0000001en

AWARNING

Warning (the word “WARNING” is in

black letters with an orange rectangle

behind it) – indicates a potentially

hazardous situation which, if not

avoided, could result in death or serious

injury.

0000001en

ACAUTION

Caution (the word “CAUTION” is in black

letters with a yellow rectangle behind it)

– indicates a potentially hazardous

situation which, if not avoided, may

result in minor or moderate injury.

0000001en

CAUTION

Caution without the safety alert symbol

indicates a potentially hazardous

situation that can cause damage to the

machine, personal property and / or the

environment or cause the machine to

operate improperly.

0000001en

SAFETY

2-2 BY Service Manual

Safety Precautions

SAFETY PRECAUTIONS

ADANGER

SCALD HAZARD!

• NEVER remove the coolant filler cap if

the engine is hot. Steam and hot

engine coolant will escape and

seriously burn you. Allow the engine

to cool before attempting to remove

the filler cap.

• Securely tighten the filler cap after

checking the coolant level. Steam can

escape during engine operation if the

cap is loose.

• Failure to comply will result in death or

serious injury.

0000002enMarine

ADANGER

EXPLOSION HAZARD!

• Keep the area around the battery

well-ventilated. While the engine is

running or the battery is charging,

hydrogen gas is produced which can

be easily ignited.

• Keep sparks, open flame and any other

form of ignition away while the engine

is running or battery is charging.

• Failure to comply will result in death or

serious injury.

0000003en

ADANGER

CRUSH HAZARD!

• ALWAYS use the engine lifting eyes

when lifting the marine engine. The

lifting eyes are engineered to lift the

weight of the marine engine only.

• ALWAYS use lifting equipment with

sufficient capacity to lift the marine

engine. Additional equipment is

necessary to lift the marine engine and

marine gear together.

• NEVER stand under hoisted marine

engine. If the hoist mechanism fails,

the marine engine will fall on you,

causing serious injury or death.

• Failure to comply will result in death or

serious injury.

0000026en

ADANGER

CRUSH HAZARD!

• NEVER stand under hoisted engine. If

the hoist mechanism fails, the engine

will fall on you, causing death or

serious injury.

• Failure to comply will result in death or

serious injury.

0000033enMarine

SAFETY

BY Service Manual 2-3

Safety Precautions

ADANGER

FIRE HAZARD!

• Keep fire extinguishers handy in case

of fire. Clearly indicate the location of

the fire extinguishers with a safety

sign.

• Ensure that the type of fire

extinguishers are appropriate for

material that might catch fire. Check

with local authorities.

• Have all fire extinguishers checked

periodically for proper operation

and / or readiness.

• Post evacuation routes prominently.

Periodically conduct fire drills.

• Ensure that appropriate fire detection

and extinguishing equipment are

installed and checked periodically for

proper operation. Check with local

authorities.

• Failure to comply will result in death or

serious injury.

0000018en

ADANGER

FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive

under certain conditions.

• NEVER remove the fuel cap with the

engine running.

• Failure to comply will result in death or

serious injury.

0000011en

ADANGER

FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive

under certain conditions.

• When you remove any fuel system

component to perform maintenance

(such as changing the fuel filter) place

an approved container under the

opening to catch the fuel.

• NEVER use a shop rag to catch the

fuel. Vapors from the rag are

flammable and explosive.

• Wipe up any spills immediately.

• Wear eye protection. The fuel system

is under pressure and fuel could spray

out when you remove any fuel system

component.

• Failure to comply will result in death or

serious injury.

0000009en

ADANGER

FIRE AND EXPLOSION HAZARD!

• Diesel fuel is flammable and explosive

under certain conditions.

• NEVER use diesel fuel as a cleaning

agent.

• Failure to comply will result in death or

serious injury.

0000012en

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